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Structure and implementation of emergency response plans for HF cloud releases in an Alkylation Unit

Kioufis Marios-Ioannis

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Summary

This thesis refers to the design, the analysis and the construction of models for leakage scenarios of the chemical toxic bond of Hydrogen Fluoride (HF), which is use as catalyst in the Alkylation processes, and during these processes, some petrol’s components are produced. This kind of leakage are rare, but they still may take place and for this reason, they must be studied, a priori, for their damage control, because of the increased danger and their consequences on the human.The examined scenarios are three (3), in distinguishable points of the process with different composition and HF content, which lead to the graduate analysis of scenarios with low, medium and high level of danger. The danger is related and captured on the size and the dynamic of the reply of the cluster, which depends on the weather conditions and on the means and measures implemented for the limitation of the spreading.The scenarios are on the real-time data, whose source is the existent Alkylation facility of an Oil Refinery. In each scenario, it is imprinted the dynamic reply of the HF cloud’s expansion for different weather conditions, according to the time, when the leakage started. Also, the current Emergency Response Plans (ERP) of the facility are examined and imprinted, as well as the functional procedures for a potential leakage limitation.Moreover, the architecture of the ERP is developed and the analysis of the coordination of the action, which are included in the Overall Emergency Plan (OEP) of the company. The development of the dynamic response and depiction models of this kind of events constitute the data base for the effective deployment of action plans and as a result the rapid and purposeful reaction for the immediate control of the accident.In the present assignment the scenarios’ analysis is based on the risk-reaction criteria and the appropriate actions are presented according to each factor and spreading scenario. Specific actions, executive systems for leakage and incident control are proposed, according and additional to the current systems and procedures.To conclude, the danger of these HF leakage situations and their effectiveness confrontation with the existing means, is ascertained. Additionally, the proposals, for the improved creation of additional restrain zones and means of protection for the staff, because of the toxicity of the HF, are recorded.

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