Tk12 Report Assignment3

UNIVERSITAS INDONESIA
THE ELECTROCHEMICAL EXTRACTION OF LITHIUM FROM

BRINE FOR LITHIUM CARBONATE PRODUCTION
Report Assignment III
GROUP TK 12
GROUP PERSONNEL:
FARADILLA ANDIANI P. (1606886173)
JESSICA ADELINE S. (1606879943)
M. AZKIA RIFQI A. (1606891223)
SULTAN SHIDDIQI S. (1606905374)
TITA TRI YOLANDINI (1506673403)
CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
UNIVERSITAS INDONESIA
NOVEMBER 2019
EXECUTIVE SUMMARY
The main processes of this electrochemical extraction of lithium from brine

for lithium carbonate production include evaporation, electrochemical extraction,
reaction, and purification. These processes are also supported by utilities such as
steam and cooling water. In other words, the entire plant involves gas phase (steam),
liquid phase, and solid phase (in slurry form). To convey them all, a piping system
is necessary to be made. Since the fluid conveyed is various, there are varieties in
the piping system such as the thickness and diameter. This would lead to schedule
determination. Meanwhile, to decide the pipe diameter, a simple calculation using
volume flow rate and fluid velocity (rule of thumb) are used. However, the
specification from vendors is chosen. The material used is ASME B36.10 Carbon
Steel Pipes 40cr which is carbon steel pipe with chromium in it to prevent corrosion,
and also with coating to increase corrosion resistance. This is chosen since it is more
economical than stainless steel. The pressure drop of pipes is also calculated based
on the pipe length.
Moving on, instrumentation has to be considered because it is important to
keep the process on track and optimum. With instrumentation control, all process
will be working as planned and safe, with sudden surge or decrease in production
anticipated. Basically, each control system consists of a transmitter and controller.
The transmitter, with sensor, will give electric signal to the controller if there are
changes needed to be made. The controller will send pneumatic signal to control
the valve opening. There are two control valve action: air to open and air to close.
This will be chosen according to safety and economy if failure happens. Control
system in the plant includes temperature, flow, and level control.
Overall, main processes, utility, equipment sizing, and P&ID have been
made. It is also important to understand about process and plant safety, because
safety is number one. Therefore, a detailed description of health, safety, and
environment is made, including HAZID (Hazard Identification Study), HAZOP
(Hazard and Operability Study), operational details, personal protective equipment,
maerial safety data sheet, area classification, and waste management. According to
the safety analysis, it is found that………..nanti lanjut lagi kalau dah kelar.
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iii Universitas Indonesia
TABLE OF CONTENT
EXECUTIVE SUMMARY................................................................................... ii
TABLE OF CONTENT ....................................................................................... iv
LIST OF FIGURES .............................................................................................. v
LIST OF TABLES ............................................................................................... vi
1 CHAPTER 1 PIPING AND INSTRUMENTATION DIAGRAM ........... 1
1.1 Pipeline Specification ............................................................................... 1
1.2 Production Process Control Description .................................................. 4
1.3 Utility Control Description....................................................................... 6
1.4 Production Process Piping and Instrumentation Diagram ........................ 6
1.5 Utility Piping and Instrumentation Diagram ............................................ 7
2 CHAPTER 2 HEALTH, SAFETY, AND ENVIRONMENTAL
PROTECTION ...................................................................................................... 8
2.1 Hazard Identification Study (HAZID) ..................................................... 8
2.2 Hazard and Operability Study (HAZOP) ............................................... 16
2.3 Operational Details ................................................................................. 27
2.3.1 Commissioning ............................................................................... 27
2.3.2 Start-up Procedure .......................................................................... 30
2.3.3 Shutdown Procedure ....................................................................... 36
2.4 Personal Protective Equipment (PPE) .................................................... 39
2.5 Material Safety Data Sheet (MSDS) ...................................................... 42
2.6 Area Classification ................................................................................. 48
2.7 Emergency Action Plan .......................................................................... 48
2.7.1 Evacuation Procedures, Escape Routes, and Floor Plans ............... 49
2.7.2 Medical Emergency Plan ................................................................ 50
2.7.3 Fire Fighting Strategy ..................................................................... 50
2.7.4 Emergency Operation Training ....................................................... 51
2.7.5 Policies for Updating and Maintaining the EAP ............................. 53
2.8 Waste Management ................................................................................ 53
2.8.1 Solid Waste ..................................................................................... 54
2.8.2 Liquid Waste ................................................................................... 55
2.8.3 Gas Waste ....................................................................................... 56
2.8.4 Sound .............................................................................................. 56
3 CHAPTER 3 PLANT LAYOUT ............................................................... 58
3.1 Plant Location ........................................................................................ 58
3.2 Plant Layout ........................................................................................... 59
3.2.1 General Consideration of Plant Layout ........................................... 59
3.2.2 Safe Range Between Equipment ..................................................... 59
3.2.3 Area Classification Layout ............................................................. 60
3.2.4 Overall 2D Plant Layout ................................................................. 60
3.2.5 Overall 3D Plant Layout ................................................................. 60
4 CHAPTER 4 CONCLUSION .................................................................... 61
5 REFERENCES ............................................................................................ 62
6 APPENDICES A ......................................................................................... 66
7 APPENDICES B ......................................................................................... 70
8 APPENDICES C ......................................................................................... 74
9 APPENDICES D ......................................................................................... 76
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LIST OF FIGURES
Figure 1.1. Lithium Carbonate ............................... Error! Bookmark not defined.

Figure 1.2. Mechanism of Salt Capturing Battery System for Lithium Extraction (2
steps) ....................................................................................................................... 6
Figure 1.3. Mechanism of Salt Capturing Battery System for Lithium Extraction (4
steps) ...................................................................... Error! Bookmark not defined.
Figure 1.4. Circular Integral Shape of Energy Consumed per Cycle ............ Error!
Bookmark not defined.
Figure 1.5. Schematic representation of selective-exchange battery systems: (a)
FePO4/NiHCF battery and (b) λ-MnO2/Zn battery Error! Bookmark not defined.
Figure 1.6. Schematic diagrams of the electrochemical lithium recovery process
with the LMO-Zn system. (a) Discharging step (b) Charging step ............... Error!
Figure 1.7. The schematic of LiFePO4/FePO4 rocky-chair battery system.
Reproduced from He et al., 2018 with permission Error! Bookmark not defined.
Figure 1.8. Global lithium consumption in all related commodities and their
contributions in the batteries (2010–2025) ............ Error! Bookmark not defined.
Figure 1.9. Plant location ...................................................................................... 58
Figure 2.1. Lithium Carbonate Fabrication in Laboratory ScaleError! Bookmark
not defined.
Figure 2.2. Schematic Representation of the ReactorError! Bookmark not
defined.
Figure 2.3. Batch Stirring Steam Jacketed ReactorError! Bookmark not defined.
Figure 2.4. Block Flow Diagram ........................... Error! Bookmark not defined.
Figure 2.5. Process Flow Diagram of Brine EvaporationError! Bookmark not
defined.
Figure 2.6. Process Flow Diagram of Lithium Carbonate Synthesis ............. Error!
Figure 4.1. Composite Curves ............................... Error! Bookmark not defined.
Figure 4.2. Relative Temperature Change of One Fluid to Another ............. Error!
Figure 4.3. Infeasible and Feasible cascade ........... Error! Bookmark not defined.
Figure 4.4. Heat Exchanger Network Design ........ Error! Bookmark not defined.
Figure 4.5. Process Flow Diagram After HEN ...... Error! Bookmark not defined.
Figure 5.1. Plant Location for Seawater Source .... Error! Bookmark not defined.
Figure 5.2. PFD of Cooling Tower ........................ Error! Bookmark not defined.
Figure 5.3. PFD of Steam Generation .................... Error! Bookmark not defined.
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LIST OF TABLES
Table 2.1. Process Selection Parameter ................. Error! Bookmark not defined.
Table 2.2. Process Selection Matrix ...................... Error! Bookmark not defined.
Table 2.3. Electrode Pair Selection ........................ Error! Bookmark not defined.
Table 2.4. Kinetic Parameter Values for Lithium Chloride Carbonation ...... Error!
Table 2.5. Operating Conditions and Mass Balance of Brine Evaporation ... Error!
Table 2.6. Operating Conditions and Mass Balance of Lithium Carbonate Synthesis
................................................................................ Error! Bookmark not defined.
Table 3.1. Mass Balance of E-101 ......................... Error! Bookmark not defined.
Table 3.4. Mass Balance of R-201 ......................... Error! Bookmark not defined.
Table 3.5. Mass balance of M-201 ......................... Error! Bookmark not defined.
Table 3.6. Mass balance of M-202 ......................... Error! Bookmark not defined.
Table 3.7. Mass Balance of R-202 ......................... Error! Bookmark not defined.
Table 3.8. Mass Balance of F-201 A/B/C .............. Error! Bookmark not defined.
Table 3.9. Mass Balance of V-201 ......................... Error! Bookmark not defined.
Table 3.10. Energy Balance in Evaporation ProcessError! Bookmark not
defined.
Table 3.11. Energy Balance in Extraction Process Error! Bookmark not defined.
Table 3.12. Energy Balance in Drying Process ..... Error! Bookmark not defined.
Table 3.13. Total Energy Balance .......................... Error! Bookmark not defined.
Table 3.14. Overall Mass Balance of Brine EvaporationError! Bookmark not
defined.
Table 3.15. Overall Mass Balance of Lithium Carbonate Synthesis ............. Error!
Table 4.1. Streams Involved in Heat Exchanger NetworkError! Bookmark not
defined.
Table 4.2. Minimum Utility Requirement ............. Error! Bookmark not defined.
Table 4.3. Shifted Temperature Data ..................... Error! Bookmark not defined.
Table 4.4. The CP of Each Streams ....................... Error! Bookmark not defined.
Table 4.5. Cascade Table ....................................... Error! Bookmark not defined.
Table 4.6. Heat Exchanger Network Design Rule . Error! Bookmark not defined.
Table 4.7. Heat Exchanger Network Final Design Error! Bookmark not defined.
Table 4.8. Mass Flow and Operating Conditions After HENError! Bookmark
not defined.
Table 5.1. Cooling Water Requirement Before HENError! Bookmark not
defined.
Table 5.2. Calculation of Makeup Cooling Water Before HENError! Bookmark
not defined.
Table 5.3. Cooling Water Requirement After HENError! Bookmark not defined.
Table 5.4. Calculation of Makeup Cooling Water After HENError! Bookmark
not defined.
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Table 5.5. Steam Requirement in Plant Before HENError! Bookmark not
defined.
Table 5.6. Steam Requirement in Plant After HENError! Bookmark not defined.
Table 5.7. Electricity Requirement After HEN...... Error! Bookmark not defined.
Table 5.8. Utility Requirement Comparison .......... Error! Bookmark not defined.
Table 5.9. Mass Balance for Cooling Water .......... Error! Bookmark not defined.
Table 5.10. Mass Balance for Steam Generation ... Error! Bookmark not defined.
Table 5.11. Energy Balance for Utility Section ..... Error! Bookmark not defined.
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1 CHAPTER 1
PIPING AND INSTRUMENTATION DIAGRAM
1.1 Pipeline Specification

Pipes are used to convey flowing substances such as liquid and gases. In this
plant, pipe is also used to deliver slurry solution which contains solid product
emerged in the liquid brine. The main function of this is to transport fluid point to
point, from bottom to top, vice versa.
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Table 1.1. Pipeline Specification Area 100
Inner Outer
Nominal Pipe Length Pressure Drop
Pipe Code Material Diameter Diameter Schedule
Size (inch) (ft) (psi/100 ft)
(mm) (mm)
101 Carbon Steel A53 A106 API5L 278.52 288.83 12.00 40 15.00 0.3024
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
2

Inner Outer
(mm) (mm)
202 128.194 141.3 5 40
203 52.501 60.325 2 40
204 52.501 60.325 2 40
205 40.894 48.26 1.5 40
206 62.713 73.025 2.5 40
207 62.713 73.025 2.5 40
211 20.93 26.67 0.75 40
212 62.713 73.025 2.5 40
214 95.504 101.6 3.5 40
215 477.82 508 20 40
217 477.82 508 20 40
218 12.523 17.145 0.375 40
219 52.501 60.325 2 40
220 35.052 42.164 1.25 40
221 62.713 73.025 2.5 40
222 40.894 48.26 1.5 40
223 6.846 10.3 0.125 40
224 15.798 21.336 0.5 40
225 333.34 355.6 14 40
226 333.34 355.6 14 40
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3

Inner Outer
(mm) (mm)
302
303
304
305

Inner Outer
(mm) (mm)
402
403
404
405
406
4
1.2 Production Process Control Description

Table 1.5. Process Control Area 100
Process Controlled Controlling
Controller Function Control Procedure
Equipment Parameter Parameter
Temperature transmitter will give electric
signal to the controller if there’s anomaly in
Heat Cooling Control temperature of
Temperature stream’s temperature. The controller will
Exchanger Temperature Water Flow concentrated brine for further
Control send pneumatic signal to cooling water
(E-106) Rate treatment (Area 200).
stream valve opening and control it.
Control Valve Action: AC (Air to Close)
Temperature transmitter will give electric
signal to the controller if there’s anomaly in
Evaporator Control temperature of the first
Temperature the column temperature. The controller will
First Effect Temperature Steam evaporator to ensure suitable
Control send pneumatic signal to steam stream valve
(E-103) evaporation happens.
opening and control it.
Control Valve Action: AO (Air to Open)
Level transmitter will give electric signal
Multi
maintain certain liquid level. The controller
Effect
Liquid Out Control stable liquid output will send pneumatic signal to set the output
Evaporator Level Level Control
Flow with level control. liquid valve opening. Stable liquid level
(E-103, E-
means stable liquid output.
104, E-105)
5
Table 1.6. Process Control Area 200

Level transmitter will emit pneumatic
Control the level of liquid in signal to prevent level in the
Concentrated
Level Level Control electrochemical reactor to electrochemical reactor reach more than
brine flow
make stable process 85% of volume capacity
Electrochemical Control Valve Action: AO (Air to Open)
Reactor (R- Control the flow of water
Flow transmitter will emit pneumatic
201) from storage to decrease the
signal to control the flow rate of water
concentration of recycled
Flow Rate Water flow Flow Control before mix with lithium chloride
lithium chloride solution to
solution.
keep the concentration
constant at desired value
Temperature transmitter will emit
Control the flow of steam
Carbonation pneumatic signal to control the flow rate
Temperature before enter carbonation
Reactor (R- Temperature Steam flow of steam before entering the carbonation
Control reactor jacket to make stable
202) reactor jacket
temperature process
Temperature transmitter will emit
Air Heater (E- Temperature pneumatic signal to control the flow rate
Temperature Steam flow before enter air heater to
201) Control of steam before entering the air heater
make stable air temperature
6
1.3 Utility Control Description

Table 1.7. Utility Control Area 300
Flow transmitter will send electric signal and
Cooling Makeup Control the flow of makeup the controller will give pneumatic signal to
Tower Flow Rate Water Flow Flow Control water from T-2 to fulfil cooling the control valve indicating how much
(CT-301) Rate water requirement. makeup water is needed.
Table 1.8. Utility Control Area 400

Flow transmitter will emit pneumatic signal
Steam to control the flow rate of steam condensate
condensate make-up before
Boiler (B- Flow Rate Flow Flow Control make-up before entering pump and steam
enter steam boiler to make
401) boiler
stable water feed
1.4 Production Process Piping and Instrumentation Diagram

xxx
Figure 1.1. Process Piping and Instrumentation Diagram Area 100

Figure 1.2. Process Piping and Instrumentation Diagram Area 200
7
1.5 Utility Piping and Instrumentation Diagram

Figure 1.3. Utility Piping and Instrumentation Diagram Area 300
Figure 1.4. Utility Piping and Instrumentation Diagram Area 400
2 CHAPTER 2
HEALTH, SAFETY, AND ENVIRONMENTAL PROTECTION
2.1 Hazard Identification Study (HAZID)

Hazard Identification (HAZID) Study is a qualitative technique for the early
identification of potential hazards and threats effecting people, the environment,
assets or reputation. The major benefit of a HAZID study is to provide essential
input to project development decisions. It is a means of identifying and describing
HSE hazards and threats at the earliest practicable stage of a development or
venture.
The HAZID study is a technique for early identification of hazards and threats
and can be applied at the conceptual or detailed design stage. Early identification
and assessment of hazards provides essential input to project development decisions
at a time when a change of design has a minimal cost penalty. A HAZID study is
carried out by an experienced multi-discipline team using a structured approach
based on a checklist of potential hazards. Potential problems are highlighted for
action outside the meeting. Typical process hazards are considered such as
environmental, geographical, process, fire and explosion, health (Halliburton,
2015).
Figure 2.1. HAZID Process

(Source: Halliburton, 2015)
HAZID studies has its objectives, as listed down below:
1. Identify to the host facilities due to design, and evaluate potential
consequences should the hazards be realized.
2. Establish safeguards to manage hazards, identify areas where further
understanding of safeguard effectiveness is needed.
3. Make recommendations to reduce the likelihood of hazard occurrence or
mitigate the potential consequences.
HAZID studies method, accepted as one of the best techniques for identifying
potential hazards and operability problem, involves the following:
1. Assembly of a team of experienced project personnel.
2. Presentation detailing the scope of the HAZID.
3. Identifying hazards, cause, consequences and safeguards.
Table 2.1. Hazard Severity Parameter for HAZID

Parameter Minor Major Severe
Human Resources No injury Medium injury fatal injury
Losses around
Losses under USD Losses over
Assets USD 100,000-
100,000 USD 1,000,000
1,000,000
small Massive
No environmental
Environment environmental environmental
damage
damage damage
(Source: McKay, 2017)
Table 2.2. Hazard Frequency Parameter for HAZID

Parameter Most Likely Likely Unlikely
Very Likely
Likely (1-10
Unlikely (Once or not (more than 10
Frequency times in 10
at all in 10 years) times in 10
years)
years)
(Source: McKay, 2017)
Hazard identification is then simulated by the guidewords, which formulates

the scenarios where the design intent might be violated and therefore centers on the
lateral thought processes. The objective is to define how an event could happen and
what would then be the consequences. Hazard index is then measured as the product
of severity and frequency, as stated below.
Table 2.3. Hazard Index Based on Frequency and Severity
Severity
Frequency
Minor Major Severe
Very Likely Medium High Extreme
Likely Low High Extreme
Unlikely Low Medium High
(Source: Queensland Coke & Energy, 2005)
The HAZID analysis of the plant is described as the following.
Table 2.4. Plant Hazard Identification (HAZID)
Existing Hazard
No Guideword Cause Consequences Severity Frequency Action Comments
Controls Index
Brine Evaporation
1 Accident  Falls caused by Slippery floors and Tank level Major Unlikely Medium Monitoring tank
Hazards slips, water puddle on control, PPE level regularly,
particularly on floors, Operators Making sure
floors made injury operators are well
slippery as a equipped with PPE,
result of Ensuring strict
extensive use of working procedure
water
 Falls from
elevated places
throughout
inspection of
evaporators
 Capture of parts
of body between
various parts of
evaporator
Table 2.5. Plant Hazard Identification (HAZID) (continued)
Existing Hazard
Controls Index
Exposure to
excessive heat
and high
humidity, due to Operators’ fatigue Making sure
Physical
2 wide use of and thermal PPE Major Unlikely Medium operators are well
Hazards
steam exhaustion equipped with PPE
Exposure to
high noise levels
Damage of the Regular

3 Damage Bad construction Major Unlikely Medium Inspecting regularly
evaporator unit maintenance
Friction in moving Nuisance noise Very Using earplug as

4 Noise PPE Minor Medium
parts of pump issue Likely PPE
Lithium Carbonate Synthesis
Friction in moving Nuisance noise Very Using earplug as

1 Noise PPE Minor Medium
parts of pump issue Likely PPE
Existing Hazard
Controls Index
Small electrodes’ Fire and explosion Ignition
Fire and Ensuring strict
2 gap inducing in electrochemical source Severe Unlikely High
Explosion working procedure
electrical spark reactor control
Damage of the
Regular
3 Damage Bad construction Lithium Carbonate Major Unlikely Medium Inspecting regularly
maintenance
Synthesis unit
PPE, Proper Inspecting regularly,
High voltage Operators can be cable Making sure
Electrocuted unit electrocuted, Fire insulation, operators are well
4 Severe Unlikely High
and Fire Short circuit in electrochemical Neatly equipped with PPE,
reactor arranged Ensuring strict
cables working procedure
High Making sure
temperature Burns, Capture of
operators are well
Accident surface parts of body
5 PPE Severe Unlikely High equipped with PPE,
Hazards High speed between in the
Ensuring strict
rotation reactor
working procedure
Utility
Inspecting and
Boiler blowout and Temperature monitoring
1 Damage High temperature Severe Unlikely High
explosion control temperature
regularly
Existing Hazard
Controls Index
Regular inspection
Flammable
Fire and Fire and explosion Flue gas and monitoring,
2 composition of Severe Unlikely High
Explosion around boiler control ensuring no ignition
gases in boiler
source nearby
Damage of the Regular

3 Damage Bad construction Major Unlikely Medium Inspecting regularly
Utility units maintenance
Cooling water
Cooling Heat release of failure (cooling Temperature Regular inspection
4 Major Unlikely Medium
water failure water water is hotter than control and monitoring
usual)
Entire Site Overview
Corroding Material
Regular corrosion
Piping substance inside Corrosion leading selection,
1 Major Likely High inspection, applying
Corrosion pipe, external to leakage corrosion
corrosion inhibitor
weather factor allowance
Control Room
Error in control Tight
Implementing
System system or Operational working
1 Severe Likely Extreme working procedure
Error equipment, human disruption procedure,
more strictly
error training
Existing Hazard
Controls Index
Laboratory
Hazardous
Chemical spill, substance affecting Working Tight laboratory
1 Toxic Major Likely High
unwanted reaction people in procedure working procedure
laboratory
Tight laboratory
Chemical reaction
Explosion in Working working procedure,
2 Explosion leading to Major Unlikely Medium
laboratory procedure providing fire
explosion
extinguisher
Office and Technical Building
Electrical spark, Evacuation HSE training for
Fire in office and
1 Fire fire spread from guide, fire Severe Unlikely High office and technical
technical building
plant hydrant building workers
2.2 Hazard and Operability Study (HAZOP)
Hazard and Operability Analysis (HAZOP) is a structured and systematic
technique for system examination and risk management. In particular, HAZOP is
often used as a technique for identifying potential hazards in a system and
identifying operability problems likely to lead to nonconforming products. HAZOP
is based on a theory that assumes risk events are caused by deviations from design
or operating intentions. Identification of such deviations is facilitated by using sets
of “guide words” as a systematic list of deviation perspectives. This approach is a
unique feature of the HAZOP methodology that helps stimulate the imagination of
team members when exploring potential deviations.
As a risk assessment tool, HAZOP is often described as:
 A brainstorming technique.
 A qualitative risk assessment tool.
 An inductive risk assessment tool, meaning that it is a “bottom-up” risk
identification approach, where success relies on the ability of subject matter
experts (SMEs) to predict deviations based on past experiences and general
subject matter expertise.
HAZOP is best suited for assessing hazards in facilities, equipment, and
processes and is capable of assessing systems from multiple perspectives:
1. Design
 Assessing system design capability to meet user specifications and safety
standards
 Identifying weaknesses in systems
2. Physical and operational environments
 Assessing environment to ensure system is appropriately situated,
supported, serviced, contained, etc.
3. Operational and procedural controls
 Assessing engineered controls (ex: automation), sequences of operations,
procedural controls (ex: human interactions) etc.
 Assessing different operational modes – start-up, standby, normal
operation, steady & unsteady states, normal shutdown, emergency
shutdown, etc.
HAZOP is performed by a group of experts from multiple disciplines and
led by an experienced safety specialist or training consultants. The main HAZOP
procedures are (Timmerhaus, 1991):
1. Collecting all process lineation for each process in the plant.
2. Process breakdown into little and more detail sub-process. To clarify the
breakdown of sub-process is given nodes in upper-ends of each sub-process.
There is no particular rule about limiting the distance of process.
3. Searching all possibilities of deviation in each process through uses of
systematic questions (HAZOP model for question is made by using
keywords, intended to make the analysis process easier).
4. Scoring for each negative effect that caused by every deviation mentioned
before. The criterion of harmful degrees for those negative effects is
determined by safety and efficiencies operational condition of the plant in
normal condition.
5. Determination of overcome action to every deviation happened.
We use two groups of keywords to emphasize systematic question in
HAZOP procedure, which are
1. Primary Keywords
Primary keyword is every word that is related to condition or parameter of a
process. For example: flow, pressure, temperature, viscosity, corrosion,
erosion, level, density, relief, composition, addition, and reaction
2. Secondary Keywords
Secondary keywords are every word which is merged with primary keyword
will shows probability of deviation that can be happened. For example: no,
more, less, reverse, and as well as.
HAZOP analysis of the plant and office is shown in the tables below.
Table x. Plant Hazard and Operability Study
Operation Unit Consequence/
Parameter Deviation Possible Causes Prevention/ Action Control
Units Code Hazard
Pump fails Material quantity
Flow
(electrical or target is not Controlling the flow
Low Indicator
mechanical), valve accomplished, sales of the stream
Control
shut interrupted
The product
Controlling the flow
specification is
Flow Overworked pump, of the stream to
overwhelmed and can
valve is not prevent feed loss in Flow
not be controlled,
E-103 High working (open high pressure pump Indicator
possible overheating
Evaporator E-104 widely, and reverse osmosis Control
pump, the impurities
E-105 uncontrolled) and installing safety
harms the next
valve
process, flooding
Controlling the
The source is concentration of
High impurities that Analyzer
disturbed (by waste before being
Concentration High will harms next Indicator
ocean wave, waste, pump to the ocean
process Control
sands) and waste water
treatment
Units Code Hazard
Under performance
Material quantity
pump (electrical or
Less target is not
mechanical), valve
accomplished
shut
Flow Overworked pump,
valve is not
Material overflow in
More working (open
the reactor, flooding
widely,
Flow
Electrochem uncontrolled) Controlling the flow
R-201 Indicator
ical Reactor Overworked pump, of the stream
Control
valve is not Product does not meet
Less working (open the minimum
widely, specification
Concentration uncontrolled)
Under performance
pump (electrical or Less production
More
mechanical), valve quantity
shut
Units Code Hazard
Feed temperature The reaction is not
is too low, steam done as far as Controlling the steam Temperatur
Less
flow is less than expected and need flow e Control
Carbonation necessary. more time to be done.
R-202 Temperature
Reactor Feed temperature
More steam is needed,
is too high, steam Controlling steam Temperatur
More reaction can’t be
flow is more than flow e Control
controlled.
necessary.
Flow from There will be no
steam after There is loss more enough steam for Controlling make up Flow
Less
usage than expected recycle back to main water flow Control
(condensate) process
Boiler B-401
Monitoring
Lack of Heat Steam doesn’t reach Temperature, Temperatur
Temperature Less
Supplier desired specification controlling the e Control
natural gas flow
Less flow of Temperature of
Heat E-101, Install High Temperatur
Flow Less cooling water, pipe process fluid remains
Exchanger E-102, Temperature Alarm e Control
blockage constant
E-106, High cooling flow,
Temperature of Install Low Temperatur
E-201 More failure of cooling
process fluid decrease Temperature Alarm e Control
water valve
Failure on control
More on Install High Pressure Pressure
Pressure valve of tube side Bursting of tube
tube side Alarm Control
stream
Leakage of Contamination,
More in
heating/cooling affecting product Proper maintenance Operator
Contamination process
fluid to process quality and further and operator alert Control
fluid line
fluid processes
Hardness of water,
Corrosion Leakage, fouling, heat Operator
Corrosion erosion corrosion, Proper maintenance
of tube transfer resistance Control
embrittlement
Units Code Hazard
Material quantity
Pump fails
target is not Flow
(electrical or Controlling the flow
Less accomplished, product Indicator
mechanical), valve of the stream
does not meet the Control
shut
specification
The product
Flow specification is
Overworked pump,
overwhelmed and can
valve is not Controlling the flow Flow
not be controlled,
More working (open of the stream to Indicator
Mixer M-201 widely, prevent feed loss Control
uncontrolled)
harms the next
process, flooding
Agitator fails
(rotates slower Product does not meet
Less than the specified the specification (does Monitoring the
RPM
Mixing operating not mixed well) agitator condition
Control
condition) regularly
Agitator fails
More Waste of electricity
(rotates faster than
the specified
operating
condition)

Operation Unit Prevention/
Parameter Deviation Possible Causes Consequence/ Hazard Control
Units Code Action
Installing a
control valve
before pump to
maintain the flow,
regular Flow
No Pump clogged Process flow is hampered
P-101 maintenance and Control
P-201 control
periodically and
Pump P-202 Flow
clean the pump
P-301
P-401 Pump blockage, Processing liquid supply
plugging or hampered, low water
Less blocking in pump supply to next unit and
so feed flowrate is there might possibility of
too low cavitation
High water supply to next
Excessive impeller unit. When the fluid flow is
performance, feed too fast, the pump will run
More
flowrate is too out of fluid and could cause
high heat and fires at the pump
so the pump can be broken
Cavitation may occur,
Suction pressure is reverse flow occur, pump Control pressure Pressure
Less
too low can't distribute the liquid to periodically Control
the next process
Pressure
Decrease the inlet
Suction pressure is flow to pump,
More Pumps quickly broken
too high switch into
secondary pump

Units Code Hazard
Under performance Material quantity
Flow
pump (electrical or target is not Controlling the flow
Filter F-201 Flow Less Indicator
mechanical), valve accomplished, sales of the stream
Control
shut interrupted
The product
specification is
Overworked pump,
overwhelmed and can
valve is not
not be controlled,
More working (open
widely,
uncontrolled)
harms the next
process, flooding
Under
High humidity level of
Less performing/not
product Install temperature Temperatur
Temperature working heater
indicator e Control
Harming the next
More Overheated heater
process
Under performance Material quantity
pump (electrical or target is not
Less
Dryer V-201 mechanical), valve accomplished, sales
shut interrupted
Flow
The product Controlling the flow
Flow Overworked pump, Indicator
specification is of the stream
valve is not Control
overwhelmed and can
More working (open
not be controlled,
widely,
uncontrolled)
harms the next
process, flooding
Cooling CT- Temperature Less Flow of reboiler Temperature of Control the Temperatur
Tower 301 hot fluid is low, operation condition temperature of stream e Indicator
under heated does not achieve, low before entering Control
stream quality specification, reactor to adjust the
low production operating condition
More Overheated stream, Overheated unit, low
flow of reboiler hot quality product
fluid is high
Flow More Fan speed is too Ineffective heat removal Increasing fan speed Temperature
slow by cold utility (make up Control
water)
27
2.3 Operational Details

To make sure that the plant is operated as optimum as possible, a standard
operating procedure has to be made. First, there is start up. Start-up is a package of
steps needed to start and operate the plant. These will act as steps to ensure no
trouble in the operation in near future (damage, leak, etc). Second, there is shut
down process. Shut down is needed for stopping the plant operation, to ensure the
plant is stopped perfectly with no possible risks. Deciding operational details will
be based on vendor’s instructor manuals and will be performed by the operators.
2.3.1 Commissioning
Before doing the regular activities involving start-up and shut-down
procedures, commissioning is needed prior plant operation. Commissioning is
needed to ensure the system is working accordingly and ready for operation.
Commissioning included mechanical, utilities, and operational testing. The
procedures described in this section shall be carried out at the completion of
construction and before initial operation of the unit or the very first operational
procedure.
2.3.1.1.Mechanical Completion and Integrity Checking
This involves checking the built system. Electrical systems,
instrumentation, and control systems checkout down by appropriately qualified
personnel. All instrumentation system should be checked against the design data as
well as to be checked for installation, calibration and operation to verification of
alarms and trips. The purpose of this activity is to ensure that all instrumentation,
alarm settings, microprocessor signals and hardwire trips pertaining to the
installation are functional. This will also check that signals from the field
instrumentation are displayed locally and are being correctly relayed to the
computer interface rack, as well as to the computer system. In all steps make sure
that the operator is wearing the standard PPE and have memorized MSDS and
evacuation route. The general start up activity for every segment in the production
process includes:
a. Inspections
The inspection of each equipment for corrosion and leak-hole, intact
piping connectivity and installation, and network integrity and alarm system is
28
a procedure that must be carried before every start up. The activity of this step
includes:
 Check line by line against flowsheet and locate all items. All piping and
instrument must be completed as per piping and instrumentation diagram
(P&ID).
 Identify the location of instruments and the connectivity of each item
 Instrument calibration is verified.
 All instruments such as level transmitter, level controller, pressure
transmitters, pressure controller, temperature transmitter, temperature
controller and etc. must be installed.
 All piping and equipment is compatible with designed pressure.
 All piping and equipment is protected against corrosion.
 Planned instrumentation is installed and operative.
b. Pressure testing
The purpose of pressure testing is to confirm the mechanical integrity of
the plant, verifying capability of containing the pressures it has been designed
to hold, ensure there are no leaks and verify that the plant can be reliably made
leak free, identify any vulnerabilities well before the plant is placed into service,
and to meet the requirements of legislation, local, international and industry
standards. It is to prove the strength of the materials and weld integrity after
completion of the construction, usually using hydrostatic testing.
Isometric drawings of all systems to be tested should be displayed on a
board and marked up as each section is tested. Hydro testing of piping and
equipment according to code requirements to confirm mechanical strength
should be carried out on groups of equipment naturally suggested by design
pressure and function. All piping should be hydro tested. Major equipment that
has already been tested as part of manufacturing may be isolated by blanks.
c. Cleaning and flushing
Check the process thoroughly to ensure screens have been installed in
front of pump suctions. Regardless of whether pipes are cleaned with water,
steam, air or nitrogen, flow velocities should be high enough to ensure that pipes
29
will be suitably scoured. Need to ensure that the debris from one piece of
equipment will not simply be flushed into another.
d. Machinery checkout
Machinery check out is the final check of each equipment. It includes:
 Indicate the location of all critical valves including valves at critical vent
and drain locations
 Check control valves, valves, and globe valves to see that they are installed
properly with respect to flow. Ensure functioning control valves, switching
valves, controllers, emergency shutdown system, etc. Ensure manual valves
are in proper positions.
 Check power supply’s functionality.
 Pumps are ready for operation: aligned, lubricated, proper rotation.
 All plant lines and equipment must be flushed, cleaned, and dewatered.
 Complete functional testing all rotating equipment.
 Do final inspection of vessels and column.
 Ensure there is no leak or any disfunctional.
2.3.1.2.Utilities Commissioning
Utilities commissioning usually represents the first phase of commissioning,
as these usually need to operational first, before the rest of the plant can be
commissioned. Below are the steps taken to complete urilities commissioning:
 Check supply pressures of all services (steam, cooling water).
 At the most distant points, open drains, vent valves or pipe flanges and
purge until fluids come out clean and rust free.
 Purge/blow out lines to each piece of equipment.
 Circulate water to waste water system until water lines clear and clean.
 Flush waste water and drain systems to ensure no blockages.
 Check operation of steam traps.
 Drain condensate to waste water until it is clean.
2.3.1.3.Operational Testing
Operational testing is not necessarily be done every start up, but it is
required to maintain the sustainability of production process, to ensure plants
productivity. Periodically of 2-3 weeks, the production process is ideally sufficient
30
for an operational testing. Before operational testing carried out, the mechanical dry
running of individual pieces of equipment and hot testing must be complete first.
Tests should continue for several days to give all shifts a chance to conduct the
same tests. All shifts should be given the opportunity to start up and shutdown each
closed loop test.
2.3.2 Start-up Procedure
2.3.2.1. General Start Up Procedure
After the commissioning phase is completed, the plant can be declared
ready by the start-up phase. The general start-up procedure is listed below.
 Make sure all the raw material is enough for the operation
 Check the electricity supply.
 Load catalyst into the reactor. The reactor should be purged beforehand.
 All parameters in instrument which need controls must be set, such as
pressure, temperature, and level. This step is done to ensure the equipment
is under controlled.
 The reactor is then prepared to be ready for the process. This step involves
maintaining temperature and pressure to avoid process shock in the reactor.
 Open all inlet valves for process fluid flow in the plant.
 Open utility valve for cooling water and steam.
 Turn on all rotating equipment such as pump and compressor.
 Monitor strictly for the first five hours to ensure the process condition is
similar to that of specified in the design.
 Start-up procedure can be repeated if there is significant process deviation.
closed loop test.
2.3.2.2. Electrochemical Reactor
For electrochemical reactor, the start-up procedure is listed below
 Make sure electrode is clean from deposit and the reactor is clean from
unknown substance
 Check for leaks at every point and make sure inlet stream is flowing
smoothly and recovery solution available
 After brine water filled electrochemical reactor until 85% level, electricity
can be conducted to electrode and starting electrochemical reaction
31
 Left the reactor for 63000 second and dispose the brine water, change with
recovery solution until 85% level
 Conducted electrode again for 2100 second and product can be obtained and
let out all product flow to next process.
2.3.2.3. Evaporator
TITA
2.3.2.4. Carbonation Reactor
As for the carbonation reactor, the start-up procedure is listed below.
 Purge the reactor with nitrogen to make sure the reactor is clean.
 Check for leaks at every point and make sure the steam is flowing into the
jacket.
 Heat the reactor until temperature desired.
 Open inlet stream valve for concentrated brine and natrium carbonate
solution.
 Operate the reactor for desired reaction time.
 Open outlet stream valve to let out all products and excess reactant for
further processing.
 Purge the reactor again for cleaning.
2.3.2.5. Blower
 Do a reverse rotation check to check if the blower is working properly.
 Check the suction and discharge gauges to make sure the operating
condition is recorded properly.
 Sensor the voltages before the blower starts
 Start the blower and check the noise level, make sure it doesn’t exceed the
number of maximum noises allowed.
 Check the oil level in order for the blower to work on the highest condition.
2.3.2.6. Filter
 Give enough lubricants for the rubber so it moves easier.
 Ensure that the belt filter is properly put on the filter so the brine shall go
through the filter.
32
 Check if the indicators are in place and working properly. Clean and connect
interconnected piping. During the flushing operation, check all pipe connections
and valves for leaks. Tighten connections where necessary.
 The pump must be aligned, lubricated, and properly rotated.
 Start the feed pump
 Set the operating condition based on the optimum operating condition.
 Make sure if the output of the filter is at the desired target, if not make an
adjustment by changing the operating condition based on the design.
One of the most important things to check in filter is the particle size
distributing (PSD) because it shall be the parameter for filtering the product based
on the size of the product. In the plant, PSD consists of field-mounted sensors,
valves and trip relays, a system logic unit for processing of incoming signals, alarm
and HMI units. The system can process all input signals and activate outputs in
accordance with the applicable Cause and Effect. PSD is integrated with the control
system, such as pressure control and temperature control. When the pressure is far
from its set point, and potentially harms the equipment, human, or environment, the
PSD will automatically initiate. For example, when the temperature of the reactor
is far from the maximum temperature allowed, there will be an alarm on the
operating room for the operator to take action, but if in some cases, the level is still
getting higher, until the highest point. The process shutdown will automatically
initiate to prevent the losses.
2.3.2.7. Dryer
 Make sure all the pipes are intact and able to transport all of the feed into
the dryer.
 Put all the trays in the suitable places where the drying process will take
place.
 Turn on the blower and transport the hot air into the dryer.
 Make sure the operating condition is at the right place, or else do an
adjustment.
2.3.2.8. Conveyor
 Make sure the outlet flow of the dryer is in the right amount that suit the
capacity of the conveyor.
33
 Make sure the conveyor is plugged in so it gets the right amount of power
to move its motors.
 Give proper amount of lubricants to the machinery of the conveyor.
 Turn on the conveyor check if the solids can move properly.
2.3.2.9. Crusher
 Give enough lubricants on the motors of the crusher.
 Make sure the crusher is plugged in with enough amount of power to
accommodate.
 Turn on the crusher and make sure the PSD of the product is as the desired
target.
2.3.2.10. Pumps
Centrifugal pumps convert energy of an electric motor or turbine into
velocity or kinetic energy and then into pressure energy of the fluid being pumped.
The energy changes occur around two main parts of the pump, impeller and volute
or diffuser. Pump impeller is the rotating part that converts driver energy into the
kinetic energy. The volute or diffuser is the stationary part that converts the kinetic
energy into pressure energy. The pump driver can be either electric motor or a steam
turbine depending upon application.
These precautions must be followed before centrifugal pump start-up:
 Do not operate the centrifugal pump below the minimum rated flows or with
the suction or discharge valves closed. These conditions can quickly lead to
centrifugal pump failure and physical injury.
 Always disconnect and lock out power to the driver before you perform any
installation or maintenance tasks.
 Centrifugal pump start-up in reverse rotation can result in the contact of
metal parts, heat generation, and breach of containment.
 Flush and clean the system thoroughly to remove dirt or debris in the pipe
system in order to prevent failure at initial pump start-up.
 Bring variable-speed drivers (if installed) to the rated speed as quickly as
possible.
 Generally if the temperatures of the pumped fluid will exceed 200°F (93°C),
then warm up the pump prior to pump start-up.
34
 Circulate a small amount of fluid through the pump until the casing
temperature is within 100°F (38°C) of the fluid temperature prior to pump
start-up to avoid thermal shock to the liner and impeller and prevent damage
of mechanical seal.
General centrifugal pump start-up procedure is listed below.
 Open the suction valve.
 Open any recirculation or cooling lines.
 Fully close or partially open the discharge valve, depending on system
conditions.
 Start the driver.
 Slowly open the discharge valve until the pump reaches the desired flow.
 Check the pressure gauge to ensure that the pump quickly reaches the
correct discharge pressure.
 If the pump fail to reach the correct pressure, perform these steps:
a. Stop the driver.
b. Prime the pump again.
c. Restart the driver.
 Monitor the pump while it is operating.
a. Check the pump for bearing temperature, vibration, and noise.
b. If the pumps exceed normal levels, then shut down the pump
immediately and correct the problem.
 Repeat the last three steps until the pump runs properly.
2.3.2.11. Heat Exchangers
The general heat exchanger start-up procedure is listed below.
 Check whether all the parts such as tube shell, heads and valves of the heat
exchanger are fixed.
 Check whether all temperature, pressure and flow measuring sensors are
connected to the heat exchanger.
 Open all vent connections
 First circulate the cold stream.
 Close the vents slowly. Make sure cold stream entirely filled before closing
vents.
35
 Then circulate the hot stream and when the heat exchanger is completely
filled with the cold stream.
 Close all the vents.
 Start the operation gradually. Do not let the heat exchanger subject to
sudden temperature fluctuations
2.3.2.12. Tanks
There needs to be preparation and checking before usage of tank.
Appropriate phases should be repeated after any major repair, alteration, or
replacement during subsequent shutdowns. The phases of preparation for initial
start-up shall be according to the following steps:
 Operational checkout list.
 Hydrostatic testing.
 Final inspection of vessels.
 Flushing of lines.
 Instruments.
 Acid cleaning of compressor lines.
 Breaking in pumps.
 Breaking in compressors.
 Dry-out and boil-out.
 Catalyst loading.
 Tightness test.
The operational check-out follows the procedures listed as follow.
 Check line by line against flowsheet and locate all items.
 Identify the location of instruments.
 Indicate the location of all critical valves including valves at critical vent
and drain locations.
 Check control valves, valves, and globe valves to see that they are installed
properly with respect to flow through their respective lines. Special
attention must be given to check valves regarding their direction of flow.
 Review all piping and instrument connections for steam tracing.
36
 Check that the following facilities have been installed so that the plant can
be commissioned and put on stream: start-up bypass lines, purge
connections. stream up-connections, drains, temporary jumpovers, blinds,
check valves, filters and strainers, bleeders.
 Check pumps and compressors for start-up.
 Check sewer system for operability.
 Check blowdown systems.
 Check heater for burner installation, refractories, stack damper controls,
burner refractories, etc.
2.3.3 Shutdown Procedure
2.3.3.1. General Shutdown Procedure
Generally, there are three type of shutdown implementing in the plant,
which are initiated shutdown, process shutdown, and emergency shutdown.
Initiated shutdown is done to maintain the process equipment in plant. The
procedure is the same as stopping equipment when the process is done. Typical
procedure shutdown process can be seen on the following steps.
 Close all the inlet raw material valve
 Shut down heating and cooling sources
 Purge with nitrogen to clean each equipment
 Eliminating undesirable materials (cleaning process)
 Pressure trapped between two closed valves or closed process equipment
loops should be released immediately
 Bring the vessel to atmospheric pressure
 Shut down the electricity
A process shutdown is defined as the automatic isolation and deactivation
of all or part of a process. During a PSD, the process remains pressurized. In the
plant, PSD consists of field-mounted sensors, valves and trip relays, a system logic
unit for processing of incoming signals, alarm and HMI units. The system can
process all input signals and activate outputs in accordance with the applicable
Cause and Effect. PSD is integrated with the control system, such as pressure
control and temperature control. When the pressure is far from its set point, and
potentially harms the equipment, human, or environment, the PSD will
37
automatically initiate. For example, when the temperature of the reactor is far from
the maximum temperature allowed, there will be an alarm on the operating room
for the operator to take action, but if in some cases, the level is still getting higher,
until the highest point. The process shutdown will automatically initiate to prevent
the losses.
The term Emergency Shutdown System (ESD) refers to the method of
minimizing the consequences of emergency situations, related to typically
uncontrolled flooding or outbreak of fire in hazardous areas. Risk analyses have
concluded that the ESD system needs a high Safety Integrity Level, typically SIL 2
or 3. An emergency shutdown system represent a layer of protection mitigating and
preventing the occurrence of hazardous situation. An ESD system must be highly
reliable. During emergency, it is a must to shut down the plant in safest way. The
situations that initiate the emergency shutdown, such as
 Electric power failure
 Manual alarm
 Pump or compressor failure
The emergency shutdown is conducted with the main objectives listed as
follow.
 To shut down the plant safely
 To minimize the emission
 To prevent overpressure condition in the equipment
 To protect equipment from damage
The emergency shutdown procedure is conducted with the steps listed as
follow.
 Shutdown all transportation of gas and liquid
 Decrease the pressure and temperature of any equipment
 Perform electrical isolation
 Start all safety equipment
2.3.3.2. Electrochemical Reactor
For electrochemical reactor, the shut-down procedure is listed below
 Terminate feed flow to the reactor
 Stop electricity to electrode
38
 Clean the electrode and the reactor from impurity

2.3.3.3. Evaporator
TITA
2.3.3.4. Carbonation Reactor
As for the carbonation reactor, the shutdown procedure is listed below.
 Terminate feed flow to the reactor.
 Purge reactor with inert gas.
 Allow reactor to cool to a shutdown temperature.
2.3.3.5. Blower
 Check to ensure if all the hoses are disconnected.
 Exercise all the valves to ensure they still work properly.
 Turn off the power of the blower.
 Clean up the dust in the fan of the blower.
2.3.3.6. Dryer
 Turn off the blower and heater.
 Shut the valves in the inlet and outlet of the dryer.
 Clean up all the residues left inside the dryer.
2.3.3.7. Conveyor
 Turn off the blower and the heater.
 Shut all the valves before the inlet of the dryer.
 Turn off the conveyor motor.
 Clean up all the residue left inside the conveyor.
2.3.3.8. Crusher
2.3.3.9. Pumps
General centrifugal pump shutdown procedure follows steps below.

 Ensure that each ball valve on the 1-inch flowline that connects thepump to
the 3-inch delivery line is closed as a backup for the header check valve.
 Use the sample port valve to slowly drain off any pressure in the line, into
an acceptable container, before attempting any adjustments to the lines
connected to the pump.
39
Follow lock-out/tag-out procedures and confined space entry procedures,

in accordance with the site health and safety plan, before conducting any
maintenance activities.
2.3.3.10. Heat Exchangers
General heat exchanger shutdown procedure follows steps below.
 When heat exchanger is required to be shutdown, the hot fluid should be
turned off first.
 If it is necessary to stop the circulation of the cold fluid, the hot medium
should also be stopped by by-passing the heat exchanger.
2.3.3.11. Tanks
To evacuate the tank safely some procedure is need to be done.
 Clean any chemical from the front barrel by wiping with a clean rag and re-
attach the used nozzle. This provides an airtight seal during storage.
 Turn off all valves.
 Rewind the hose assembly without draining. Store off ground
2.4 Personal Protective Equipment (PPE)

Personal protective equipment (PPE), is the equipment that will protect the
user against health or safety risks at work. It can include items such as safety
helmets, gloves, eye protection, high-high visibility clothing, safety footwear and
safety harnesses. It also includes respiratory protective equipment (RPE). Injuries
and illnesses may result from contact with chemical, radiological, physical,
electrical, mechanical, or other workplace hazards.
All personal protective equipment should be safely designed and constructed,
and should be maintained in a clean and reliable fashion. It should fit comfortably,
encouraging worker use. If the personal protective equipment does not fit properly,
it can make the difference between being safely covered or dangerously exposed.
When engineering, work practice, and administrative controls are not feasible or do
not provide sufficient protection, employers must provide personal protective
equipment to their workers and ensure its proper use. Employers are also required
to train each worker required to use personal protective equipment to know:
 When it is necessary?
40
 What kind is necessary?

 How to properly put it on, adjust, wear and take it off?
 The limitations of the equipment?
 Proper care, maintenance, useful life, and disposal of the equipment?
Furthermore, American National Standard Institute (ANSI) has been
preparing safety standard for kind of PPE. Personal protection equipment can be
divided into 2 categories:
 General Equipment: personal protection equipment as minimum
requirements to enter the plant are safety helmet, mask, and safety shoes.
 Special Equipment: Personal Protection Equipment (PPE) is used in
accordance with the needs of employees in the workplace each based on
hazard and risk. For example: safety goggles, welding goggles, respirator,
mask, ear protection, gloves, earplugs, and so on.
There are some types of personal protection equipment summarized in the
table below:
PPE Picture Protects Hazards
Chemical liquid
splashes, dust, against
intense light, UV rays,
Safety Glasses eyes
flying objects such as
wood chips, metal
pieces
Helmet Head Falling materials
Earplugs or
Hearing Excessive noise
earmuffs
Corrosive, toxic
Gloves Hands
materials, electric wires
41
Mask and Toxic gases, vapors,

Lungs
respirator fumes or dust
Safety wear Toxic and corrosive

Skin
(coveralls) materials, electricals
Corrosive, toxic
Safety Shoes Feet material, against
crushing of toes
Personal protective equipment needs to be used when there are certain

hazards in areas of the plant or for safety use in around the plant area. These PPE
are used in order to minimize accidents from happening. There is several protective
equipment required in each area, is as stated below.
Table 2.9 Personal Protection Equipment Required per Area

No Area Classification PPE Required
Safety glasses, helmet, gloves,
1 Brine Evaporation Area
coveralls, safety shoes
Lithium Carbonate Safety glasses, helmet, coveralls,
2
Synthesis Area safety shoes
Lithium carbonate Safety glasses, helmet, gloves,
3
purification area coveralls, safety shoes
Lithium Carbonate Safety glasses, helmet, coveralls,
4
Storage Area safety shoes
Safety glasses, helmet, gloves,
5 Utility Area
coveralls, safety shoes
Raw Material Storage Safety glasses, helmet, coveralls,
6
Area safety shoes
42
7 Fire Station Helmet, coveralls, safety shoes
2.5 Material Safety Data Sheet (MSDS)

Every activity is always followed by the risks that can cause accidents,
although it should be avoided and minimized because accidents shall not happen
by itself. Accidents usually occurs by some factors; therefore, the factors shall be
determined so the right preventive actions shall be done in the most effective and
efficient ways so that accidents could be avoided. The MSDS contains much more
information about the material than the label. MSDSs are prepared by the supplier
or manufacturer of the material. It is intended to tell what the hazards of the product
are, how to use the product safely, what to expect if the recommendations are not
followed, what to do if accidents occur, how to recognize symptoms of
overexposure, and what to do if such incidents occur.
Chemicals could sometimes be poisonous and harmful for the human body.
The level of hazard is shown in the MSDS. The MSDS must be learned thoroughly
before using the chemicals. There are nine (9) categories of information that must
be present on an MSDS. These categories are specified in the Controlled Products
Regulations.
1. Product Information: product identifier (name), manufacturer and suppliers
names, addresses, and emergency phone numbers
2. Hazardous Ingredients
3. Physical Data
4. Fire or Explosion Hazard Data
5. Reactivity Data: information on the chemical instability of a product and the
substances it may react with
6. Toxicological Properties: health effects
7. Preventive Measures
8. First Aid Measures
9. Preparation Information: who is responsible for preparation and date of
preparation of MSDS
Commonly, MSDS contains chapters that explains about the chemicals that are
going to be used.
43
1. Product and Company identification

Explains about the identity of the product, and the manufacturer of the
products.
2. Composition/ Information on ingredients
Explains the composition of the chemical ingredients, concentrations, and
the chemical mixtures.
3. Hazards Identification
Includes the characteristics of danger:
 Health Dangers
Explanation of various ways chemicals can expose the user’s body
in several ways such as absorption through the skin, breathing and
etc. Information about the symptoms and health effects if the body
is in contact with these substances after the event of:
1. Effects of excessive exposure
2. Eye Contact
3. Skin Contact
4. Inhalation of Breathing
 Fire Dangers
This information determines the material included in the category
of flammable, combustible, non-combustible or other burning
materials. Ease of combustion is determined by:
1. Flash Point: the lowest temperature at which vapor can be
ignited.
2. Flammable concentration: the area of gas vapor concentration
that can be ignited. The lowest vapor concentration of a
combustible substance is called the LFL (low flammable limit)
and the highest concentration that can still be ignited is called
the UFL (upper flammable limit). The ease of combustion of
other ingredients is determined by their oxidative strength.
3. Burning Point: the temperature a which a substance burns on its
own.
 Reactivity Dangers
44
Hazardous properties due to instability or ease of decomposition,

react with other substances or polymerize that are exothermic
(generate heat) so that it is explosive or reactivity to other gases so
that it produces toxic gases.
The characteristics of the hazard are described on the scale of the
hazard as the following:
Figure 2.2 Reactivity Dangers

(Source: kelair.bppt, 2019)
a. The blue stands for the toxicity scale level
b. The red stands for fire danger scale level
c. The yellow stands for the reactivities danger scale level
d. The white stands for the other danger scale level
The classification of hazard based on NPFA uses number which

span from 0 to 4, with the description listed below.
Hazard
Number Description
Type
0 No significant risk to health
1 Irritation or minor reversible injury possible.
Health
2 Temporary or minor injury may occur.
(Blue)
Major injury likely unless prompt action is taken and
3
medical treatment is given.
45
Life-threatening, major or permanent damage may result

4
from single or repeated overexposures.
0 Materials that will not burn.
Materials that must be preheated before ignition will occur.
1 Includes liquids, solids and semi solids having a flash point
above 200°F.
Materials which must be moderately heated or exposed to
high ambient temperatures before ignition will occur.
2
Fire/ Includes liquids having a flash point at or above 100°F but
Flammability below 200°F.
(Red) Materials capable of ignition under almost all normal
temperature conditions. Includes flammable liquids with
3
flash points below 73°F and boiling points above 100°F, as
well as liquids with flash points between 73°F and 100°F.
Flammable gases, or very volatile flammable liquids with
4 flash points below 73°F, and boiling points below 100°F.
Materials may ignite spontaneously with air.
Materials that are normally stable, even under fire
0 conditions, and will not react with water, polymerize,
decompose, condense, or self-react. Non-explosives.
Materials that are normally stable but can become unstable
(self-react) at high temperatures and pressures. Materials
1
may react non-violently with water or undergo hazardous
polymerization in the absence of inhibitors.
Materials that are unstable and may undergo violent
chemical changes at normal temperature and pressure with
2
low risk for explosion. Materials may react violently with
Reactivity
water or form peroxides upon exposure to air.
(Yellow)
Materials that may form explosive mixtures with water and
are capable of detonation or explosive reaction in the
presence of a strong initiating source. Materials may
3
polymerize, decompose, self-react, or undergo other
chemical change abnormal temperature and pressure with
moderate risk of explosion.
Materials that are readily capable of explosive water
reaction, detonation or explosive decomposition,
4
polymerization, or self-reaction at normal temperature and
pressure.
(Source: NPFA, 2014)
Table 2.10 NFPA Parameter for Personal Protection

PERSONAL PROTECTION
Oxidizer: allows chemical to burn without air
OX
supply
46
Reacts with water in an unusual or dangerous

₩
manner
Simple asphyxiant gas (N2, He, Ne, Ar, Kr,
SA
Xe)
(Source: NFPA, 2014)
Table 2.11 HMIS Parameter on Personal Protection

PERSONAL PROTECTION
A
47
L-Z Site-specific label. Information from supervisor or safety specialist for

handling instructions
(Source: NFPA, 2014)
The main substances involved in the plant include hydrogen, water, oxygen,
carbon dioxide, carbon monoxide, methanol, dimethyl ether, isobutane, and
gasoline. The material safety data sheets are described in the appendix.
4. First Aid Measures

Explains about the steps of first aid if exposed or poisoned by the chemical
compound.
5. Fire Fighting Measures
The extensive countermeasures if fire occurs because of the chemical
compound.
6. Accidental Release Measures
Explains about the steps that should be taken if a chemical drip out from
the storage facility.
7. Handling and Storage
The procedures of storage and the handling of chemical.
8. Exposure Control/ Personal Protection
Personal protection by using PPE if necessary when handling certain
chemical. Which includes:
a) Breathing Protection
b) Ventilation
c) Safety Gloves
d) Eye Protection
e) Other Protective Equipment
f) Protective Supervision
9. Physical and Chemical Properties
This part explains about the information of physics and chemistry. The
influence on the surrounding conditions and indicate the limit or when the
48
material can change shape (melting, sublimation, or freezing). The

explanation of physical and chemical properties, including: boiling point,
density, vapor pressure, vapor density, freezing point or melting point,
density liquid, pH, solubility, physical appearance and odor, and so on.
10. Stability and Reactivity
Listing the nature of stability and reactivity. It contains the conditions that
must be avoided, the reaction of materials when mixed with other materials
such as water, oil, air, hazardous decomposition products, hazardous
polymerization products or other chemicals. In addition, this part will
explain the situations and conditions that must be avoided to prevent the
risk of reaction of these substances.
11. Toxicological Information
This part explains the nature of poisons to the body based on medical
chemical analysis. Possible toxicity to the body based on the results of
medical tests and reports received. Explanation of toxic properties such as
local effects, acute exposure, and chronic, including carcinogenic,
teratogenic, reproductive, mutagenic, and material interaction with drugs,
and alcohol.
12. Ecological Information and Consideration
Describe the hazards to the environment, environmental impacts,
degradation, and bioaccumulation and how to handle waste or waste
material in the form of solids, liquid or gas. This includes handling
methods.
2.6 Area Classification

xxx
2.7 Emergency Action Plan
An Emergency Action Plan (EAP) is a written procedure detailing the
appropriate response to various types of emergencies. It is an eligible written
document which has been required with the OSHA standards. An EAP can be useful
in a wide range of emergencies. The response for many emergencies will include
similar components, but they will also have unique components that will require
49
careful planning and execution. Emergency Action Plans, it is important to identify

the emergencies most likely to impact your organization and plan accordingly.
An EAP is an essential component of an organization’s safety procedures.
Creating an EAP and training employees on how to follow it can greatly reduce
employee injuries, property damage, and can ensure the safety of visitors in the
event of an emergency. Poorly prepared plan will lead to a disorganized evacuation
of emergency response that can harm the company because of employee injury and
property damage. Putting together a comprehensive emergency action plan that
deals with those issues specific to your worksite is not difficult. It involves taking
what was learned from your workplace evaluation and describing how employees
will respond to different types of emergencies, considering a specific worksite
layout, structural features, and emergency systems. Most organizations find it
beneficial to include a diverse group of representatives (management and
employees) in this planning process and to meet frequently to review progress and
allocate development tasks. There are several key components of an emergency
action plan:
 Evacuation Procedures, Escape Routes, and Floor Plans
 Medical Emergency Plan
 Fire Fighting Strategy
 Emergency Operation Training
 Policies for updating and maintaining the EAP
2.7.1 Evacuation Procedures, Escape Routes, and Floor Plans

In the event of an emergency, people need to respond quickly; knowing
where to go and how to get there is often an important part of a quick response.
Depending on the type of emergency, people will either need to exit the building as
quickly as possible or be prepared to navigate to a safer part of the building. It is
important each person knows exactly where to go in the event of an emergency. An
EAP should contain an up-to-date floor plan for the entire property. The floor plan
should include clearly marked evacuation routes and all emergency exits should be
easily identifiable. There are several categories of emergencies:
 Emergencies Within the Building
50
For emergencies occurring inside of the facility (e.g., fires, power outages,
etc.), the main goal is to get everyone out of harm way. To achieve this goal,
staff should be aware of the fastest and safest way out of the building.
 Emergencies Outside of the Building
In most cases, when an emergency starts outside of the building, the safest
thing to do is find a safe place within the building. Most often, emergencies
outside of the building will be weather-related or natural disasters.
 Health Emergencies
If someone inside of the building is injured or harmed in some way, an EAP
should be initiated quickly. Staff should be prepared to respond to a wide
range of plausible health scares such as a heart attack, seizure, possible
drowning and more.
2.7.2 Medical Emergency Plan
Whenever an employee or visitor is injured or develops a medical
emergency condition on plant property, follow the protocol below and notify your
immediate supervisor as soon as possible. Medical emergency instruction:
 Dial the plant infirmary and inform the nurse of emergency and its location
in the plant.
 If the nurse cannot be reached, dial emergency call, and inform any hospital
or fire department of the medical emergency. Give the dispatcher the nature
and location in the plant of medical emergency.
 Unless you have been designated by management to be a first aid responder,
do not provide first aid. Make the victim as comfortable as possible until
medical help arrives.
2.7.3 Fire Fighting Strategy
Fire-fighting strategy should consider the following items.
 Appointment of fire wardens, with subsequent training.
 Location plans of safety shower, fire hoses, extinguishers, and water
sources.
 Access for emergency services.
 Provision of firewater lagoons.
Fire-fighting strategy involves the following basic procedures.
51
 Arriving at the scene of the fire as rapidly as possible.

 Assessing the nature of the fire by determining its intensity and extent, the
type and abundance of fuel, the danger of entering the fire area, and the most
effective techniques for extinguishing the fire.
 Locating and rescuing endangered persons.
 Containing the fire by protecting adjacent areas; ventilating the fire area to
allow for the escape of heat and toxic gases.
 Extinguishing the fire.
The procedure carried on if a fire is occurred in our plant known as AReFo:
 Alert: Alert the occupants around the fire source by voice or pull the fire
alarm (if available and not already activated), in order to warn occupants to
evacuate.
 Report: Dial emergency numbers to call for report and help. In Indonesia
the emergency numbers are 110 – Police, 118 or 119 – Ambulance, 113 or
1131 – Fire Department, and 112 – to Indonesia’s emergency center.
Provide the following information:
 Business name and street address.
 Nature of fire.
 Fire location (building and floor).
 Type of fire alarm (detector, pull station, sprinkler waterflow).
 Location of fire alarm (building and floor).
 Name of person reporting fire.
 Telephone number for return call.
 Follow: Plant evacuation team will direct evacuation of employees and must
be followed in order to prevent any misshapen during evacuation.
2.7.4 Emergency Operation Training
In training, information about emergency operating procedures is
distributed widely and personally to every employee working on the plant or office.
The emergency procedure must entail instructions for dealing with fires, leaks, and
spills, also medical emergencies and escape procedures. By teaching each employee
this, in the case of accidents occurring, every one of them should be able to:
 Raise the alarm and call the fire brigade.
52
 Tackle fire or control spills and leaks if entirely safe to proceed.

 Evacuate the site or nearby premises.
All procedure regarding emergency action instructions must be memorized
by all workers in order to save every life in case of accidents. These instructions
consist of a four–step procedure that employees should follow during a fire
accident. This procedure must be memorized by all employees. Experience has
shown that the best response to a plant fire is first, sound the alarm, then let others
know there is a fire, then combat the fire if possible, and the last, evacuate if
necessary. The plan works best when expressed as an easily recalled acronym, such
as SAFE:
 S: Sound the alarm: Either sound it yourself or call out to someone else to
sound it. This allows the fire department to be on its way while other
activities are being performed.
 A: Alert others: Quickly tell others in the area of the fire. Do this in a calm,
firm manner. Do not cause a panic. Secure the area for the fire department.
Close all doors and windows to prevent the spread of smoke and flames.
Call security to give verification and information about location of fire.
 F: Fight the fire: Do this only in the case of a manageable fire, one that you
have the training and experience to fight. For example, fire in a wastebasket.
If it possible two employees should fight the fire together using two fire
extinguishers. If you have any doubt about your ability to fight the fire, then
do not attempt to combat it.
 E: Evacuate the area: If necessary, the burned are should be evacuated until
the authorities come. Alarm which used for evacuation system is an alarm
system standard from OSHA. It applies to provide an early warning for
emergency actions or reaction time for employees to safely escape the work
place, the immediate work area, or both. Type of alarms which used in this
plant is:
 Audible alarm which consists of horn and sirens. Horns produce a
very loud distinctive sound that immediately attracts attention. Horns
can be useful to call attention to critical situations. Signals other than
those used for evacuation purposes do not have to produce the
53
temporal coded signal. Thus, sirens produce a loud piercing wail that
makes them ideally suitable for initiating a site-wide evacuation
 Visible Alarm which consists of flashing/steady lights and strobe
lights. Steady lights are well suited for areas where ambient noise
makes audible signals difficult to hear, for an example in area where
the compressor is in. These types of lights come with different
colored covers for increased attention and can be ordered with
rotating or flashing lights. Strobe lights use high intensity flash tubes
that are ideally suited for areas where high ambient light levels make
traditional rotating or flashing lights difficult to distinguish or where
ambient noise makes audible signals difficult to hear.
2.7.5 Policies for Updating and Maintaining the EAP
Since emergencies can occur anytime without warning, it is essential to
develop a policy to train all new staff on the various EAPs and their role
within the EAP. As part of new employee training/orientation, give all new
staff a copy of the EAPs and provide them a layout of the facility along with
where all the emergency exits, and escape routes are. New staff should be
provided with important locations in the event of specific emergencies, such
as where to take shelter. Change is constant. Keeping all EAPs current is a
major undertaking, but is the only way to assure an efficient emergency
response. New hires, building redesigns, new programs, office changes,
remodeling, and much more can all impact the effectiveness of an EAP.
2.8 Waste Management
In an industry, the activities that includes the process usually produces a
residue which is called as waste. The waste from the industries need to be treated
well or else it could have an impact on the environment and/or the sustainability of
the plant production. Regulations are made by the government concerning wastes
in industrial complex based on the Human Safety Environment. The waste is
classified based on their types, which are solid waste, liquid waste, gas waste, and
also the sound (noise) waste. The waste management will be mentioned below.
54
2.8.1 Solid Waste

In the utilities section, there is a steam generation process that includes boiler
in the processes. The boiler uses fuel to boil the water and usually the process will
produce a solid waste material known as slag which is in the form of ash. Ash itself
is classified as the bottom ash and the fly ash. The fly ash contains heavy metals,
dioxin and other characteristics pollutants, therefore in some countries it considered
as a hazardous waste. It is said to have a higher risk potential than the bottom as
because the fly ash comprises higher concentration of heavy metals.
In order to handle fly ash, there are several different methods that can be
applied. The current main techniques are solidification/stabilization and thermal
methods. There are two types of S/S process, such as cement solidification and
chemical stabilization. Cement solidification requires the mixing of fly ash and
cement with water in an appropriate proportion in order to immobilize the fly ash
after cement hydration process. The chemical stabilization process is the adding of
chemical stabilizers to change the physical and chemical properties of the fly ash.
The existing forms of heavy metals in the fly ash are changed by pH control,
precipitation and adsorption, in order to reduce mobility of metals, and realize
stabilization. The plant uses this process because it does not require any additional
material which is cement and also the mass and volume of fly ash will not change
as much as the cement solidification does. The stabilizing agents that is used is
gypsum. After going through the S/S treatment, the fly ash can go to sanitary
landfills when it meets the heavy metals leaching toxicity criteria.
Thermal methods are divided into three major categories such as
vitrification, sintering and fusion. Vitrification is a chemical process whereby a
mixture of glass precursor materials and hazardous waste are melted or fused at
high temperatures to generate an amorphous, single phase product. Sintering is a
chemical process whereby a mixture of hazardous waste and small glassy are
melted at high temperature to get a glass waste form. Fusion is a chemical process
whereby the fly ash are melted or fused at high temperature in fuel furnace to form
either a crystalline or heterogeneous product. During the fusion process, organic
pollutants such as dioxins in fly ash can be decomposed, burned and gasification,
while the inorganic pollutants are melted to glassy slag. Heavy metals residue in
55
the fly ash is surrounded by a sintered glassy network structure, which effectively
control the leaching of heavy metals. This method can reduce the volume of waste
by 60% or more, and the products are resistant to leaching, which can be used as
building materials or raw materials for production of glass, ceramics.
Ash is widely used for various purposes but mainly to be used as a
replacement for materials that have a relatively low unit cost. The use of ash for hot
mix asphalt has been utilized in the United States, Japan and some European
countries. After screening and magnetic separation, ferrous and nonferrous metals
are removed from mixed ash which will then be mixed with other aggregates to be
used as a mixture of asphalt pavement. As long as there is proper handling, ash used
as asphalt will not cause environmental pollution. Besides, fly ash also contains
large amounts of SiO2 and Al2O3 and CaO which makes it to have a similar
composition of raw materials for cement production. Therefore it can also be used
as the raw materials for cement. However, washing pre-treatment of fly ash to
reduce water-soluble substances like chloride before cement curing will
significantly enhance the compressive strength and reduce the leaching toxicity of
the products. Ash can also be used for landfill cover as the environmental protection
facilities such as barrier layer and leachate recovery system. The pretreatment
process for ash such as screening, magnetic separation and particle size distribution
is unnecessary if used as landfill cover, therefore, it is a very good choice to utilize
ash for this purpose.
Before the ash is sold to the nearby cement factory, it has to be first treated
to meet the specification. Based on the list of treatment discussed above, this plant
uses the treatment of separation which will then be followed by stabilization using
thermal. After that, the ash will be ready to be transported to the nearby cement
factory and used as landfill cover. The thermal stabilization is preferred rather than
the solidification because it does not require any mixing process with cement and
the operational cost is lower.
2.8.2 Liquid Waste
Most of the liquid type waste comes from the main processes which is the
highest among other wastes in terms of number. The waste water can come from
the lithium carbonate synthesis process with the main objective is to extract the
56
lithium from water and to mix lithium with the carbonate, which we can determine
the amount of water outlet from the processes such as the electrochemical reactor
and the filtration waste. Whilst the other waste water are transported to the third
party for further treatment so that it won’t have harmful effects on to the
environment.
The liquid waste from the main process are mostly recirculated back into the
utility section so that it could be used back as the boiler feed water for the steam
generation and for the cooling water purposes. Other liquid waste is transported to
the third party.
2.8.3 Gas Waste
Throughout the whole process there is one flow of gas that is disposed and
some are recycled back into the process. The gas that is exposed into the
environment is none other than air itself that has been used as a heating medium in
the dryer unit in the lithium carbonation synthesis specifically in the purifying
process. All other gases are condensed back into the form of liquid and then
recycled back as the boiler feed water and/or as the cooling water.
Another gas waste from this plant is produced as the flue gas from the
combustion of natural gas in the steam generation process. It consists of mostly
carbon dioxide (CO2), and water vapor as well as excess oxygen (also derived from
the combustion air). It further contains a small percentage of a number of pollutants,
such as particulate matter, carbon monoxide, nitrogen oxides, and sulfur oxides.
The standard temperature and pressure for the flue gas is 50oC and 1 atm. The flue
gas for this plant has met the standard temperature and pressure. The gas residue
can be emitted directly to atmosphere because the amount of pollutans is very small.
These gas emissions have met the standards of Minister Environment
Decree No. Kep.13/Menlh/3/1995 about quality standards stationary source
emissions or BSN Standards (5000 ppm). From the standards, we can be directly
released gas waste into the environment by way of venting for CO2 emission and
hydrogen can be directly discharge into the air because it is not dangerous emission.
2.8.4 Sound
Sound can be generated by rotating equipment. Most of the operation tools in
the plant uses rotary tools such as pumps, blower, conveyor and crusher which have
57
motors and produces noise. The noise itself have levels that depends on the type of
rotary tool, capacity, performance, area and equipment operating effectiveness of
treatment or preventive maintenance programs are conducted. In order to decrease
the noise level, performing regular maintenance and replacing the parts that causes
the noise shall be done.
Noises can damage the health of personnel and also damages the mechanical
systems on the appliance. Regular maintenance and part replacements shall be
performed in order to decrease the noise level. Other actions shall be made such as
using the proper PPE for the personnel such as earplugs in the plants where noises
are made. Tools such as damper can also be applied for equipment or tools that
generates noise.
The noise standards set by the Ministry of Health is 60-70 dB and according to the
Ministry of Manpower Decree No. Kep.51/MEN/1999, the TLV (Threshold Limit
Value) for noise hazard is 85 dBA. Noise level exceeding the limit can cause
disorder includes physiological and psychological disorder. To overcome those
disorders, control of noise is needed by following procedures:
 Eliminate noise transmission to workers. To eliminate or reduce the
transmission of noise to do with insulation workers labor or machinery is to
shut down or isolate the machine or equipment that emits noise. Basically,
to cover the noisy machines are as follows: Close the engine as close as
possible, rework the doors and all the holes are acoustic. If necessary, isolate
the machine from the floor to reduce vibration propagation.
 Eliminate the noise from the sound source. Eliminating noise from the
sound source can be done by putting the marinade in a vibration source.
 Providing protection to employees. Efforts to protect employees from noise
in the work environment can be applied by wearing ear protection devices
or personal protective equipment, in the form of ear plugs and ear muffs.
58
3 CHAPTER 3
PLANT LAYOUT
3.1 Plant Location

Plant location will be related to the operation process in a plant. So, it is one
of the important things in plant design consideration. There are several factors that
must be considered because it will affect the continuity of the production of the
plant in the future. The factors can be separated into consideration of close to raw
material, proximity to markets, and land development availability. Based on those
factors, the best location that suited this plant is in Kariangau, West Balikpapan.
Figure 3.1. Plant location

(Source: Google Earth)
 Close to Raw Material

Based on the contents for making lithium carbonate that uses
electrochemical extraction process, the large amount of lithium is needed.
Pertamina is a state-owned enterprise in charge of managing oil and gas mining in
Indonesia. One of Pertamina's branches is located in Balikpapan which is Pertamina
RU V Balikpapan that produces a cooling water unit waste that contains high levels
of dissolved solids (high lithium levels). There are also many plants near the
location that uses cooling water and have cooling water returns that can be used as
an alternative source, such as PT Pupuk Kalimantan Timur that produces fertilizers
and uses quite a lot of cooling water, in an amount of 6.629.279 m3 (TIMUR, 2018).
59
Although it still needed further studies for the composition of lithium, but as the
source of seawater is close to one another (PT. Pertamina RU V and PT. Pupuk
Kaltim), it has a high possibility that the composition would be close. The plant is
located close to the sea where the location is considered based on if at any time the
supply from Pertamina RU V’s cooling water unit waste cannot be taken or it is
used up, thus there is another alternative, which is taking the raw materials from
sea water. Sea water will be contained and evaporated first for several months and
only processed when there is lack of raw material from PT Pertamina RU V and
backup PT Pupuk Kalimantan Timur.
 Proximity to Markets
Due to a huge amount of demand in consuming lithium carbonate in China
and the target market of this plant is to fulfill 1% of China’s lithium carbonate
demand, the location is determined based on the distance from China to Indonesia,
the closest to region in Indonesia to China with the availability of the raw materials
is in West Balikpapan region. The advantage of having a plant built near the sea is
that the access for shipping to destinations is easy and convenient because it is
located near the harbor where there is a lot of access to the product carrier ships.
 Land Development Availability
Lithium carbonate demand in the future will certainly increase due to the
continued development of modernization such as electronic devices, electric tools,
electric vehicles, etc. The chosen location has more area to do expansion project in
the future that considers about the demands of lithium carbonate. The expansion
project also can spread its market in the future in order to supply domestically or to
do export. So, the production later will need additional constructions to fulfill the
demands.
3.2 Plant Layout

3.2.1 General Consideration of Plant Layout
xxx
3.2.2 Safe Range Between Equipment
xxx
60
3.2.3 Area Classification Layout

xxx
3.2.4 Overall 2D Plant Layout
xxx
3.2.5 Overall 3D Plant Layout
xxx
61
4 CHAPTER 4
CONCLUSION
Based on piping and instrumentation diagram (P&ID), health, safety and

environmental protection (HSE), and plant layout report, there are several
conclusions that could be made.
 Control apa aja…
 HAZID analysis…
 HAZOP analysis.
 llalal
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6 APPENDICES A
Sodium Carbonate MSDS
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7 APPENDICES B
Lithium Carbonate MSDS
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8 APPENDICES C
Air MSDS
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9 APPENDICES D
Seawater MSDS
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78
79
80

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UNIVERSITAS INDONESIA

THE ELECTROCHEMICAL EXTRACTION OF LITHIUM FROM

Report Assignment III

CHEMICAL ENGINEERING DEPARTMENT

The main processes of this electrochemical extraction of lithium from brine

Figure 1.1. Lithium Carbonate ............................... Error! Bookmark not defined.

vii Universitas Indonesia

1.1 Pipeline Specification

Table 1.2. Pipeline Specification Area 200

Table 1.3. Pipeline Specification Area 300

Table 1.4. Pipeline Specification Area 400

1.2 Production Process Control Description

Table 1.6. Process Control Area 200

1.3 Utility Control Description

Table 1.8. Utility Control Area 400

1.4 Production Process Piping and Instrumentation Diagram

Figure 1.1. Process Piping and Instrumentation Diagram Area 100

1.5 Utility Piping and Instrumentation Diagram

2.1 Hazard Identification Study (HAZID)

Figure 2.1. HAZID Process

Table 2.1. Hazard Severity Parameter for HAZID

Table 2.2. Hazard Frequency Parameter for HAZID

Hazard identification is then simulated by the guidewords, which formulates

The HAZID analysis of the plant is described as the following.

Damage of the Regular

Friction in moving Nuisance noise Very Using earplug as

Lithium Carbonate Synthesis

Friction in moving Nuisance noise Very Using earplug as

Damage of the Regular

Table x. Plant Hazard and Operability Study

Table x. Plant Hazard and Operability Study

2.3 Operational Details

 Clean the electrode and the reactor from impurity

General centrifugal pump shutdown procedure follows steps below.

Follow lock-out/tag-out procedures and confined space entry procedures,

2.4 Personal Protective Equipment (PPE)

 What kind is necessary?

Helmet Head Falling materials

Mask and Toxic gases, vapors,

Safety wear Toxic and corrosive

Personal protective equipment needs to be used when there are certain

Table 2.9 Personal Protection Equipment Required per Area

7 Fire Station Helmet, coveralls, safety shoes

2.5 Material Safety Data Sheet (MSDS)

1. Product and Company identification

Hazardous properties due to instability or ease of decomposition,

Figure 2.2 Reactivity Dangers

The classification of hazard based on NPFA uses number which

Life-threatening, major or permanent damage may result

Table 2.10 NFPA Parameter for Personal Protection

Reacts with water in an unusual or dangerous

Table 2.11 HMIS Parameter on Personal Protection

L-Z Site-specific label. Information from supervisor or safety specialist for

4. First Aid Measures

material can change shape (melting, sublimation, or freezing). The

2.6 Area Classification

careful planning and execution. Emergency Action Plans, it is important to identify

2.7.1 Evacuation Procedures, Escape Routes, and Floor Plans

 Arriving at the scene of the fire as rapidly as possible.

 Tackle fire or control spills and leaks if entirely safe to proceed.

2.8.1 Solid Waste

3.1 Plant Location

Figure 3.1. Plant location

 Close to Raw Material