Abstract
A variety of safety issues were investigated for chemical reactors using a toluene solvent in case of a fire at small to middle scale chemical plants. The issues covered the operation of pressure-relieving valves and the subsequent discharges of the toluene to the atmosphere either directly or through an absorber, which represent the current practice at most small chemical plants. It was shown that the safety valve on the reactor may not operate within about twenty minutes after an external fire breaks out, but, once relieved, the toluene vapor released directly to the atmosphere may form a large explosion range on the ground. It was also shown that if the discharge is routed to an existing absorber used for the scrubbing of volatile organic compounds or dusts, the column may not operate normally due to excessive pressure drops or flooding, resulting in the hazardous release of toluene vapors. This study proposed two ways of alleviating these risks. The first is to ruduce the discharge itself from the safety valve by using adequate insulation and protection covers on the reactor and then introduce it into the circulation water at the bottom of the absorber through a dip linet pipe equipped with a ring-shaped sparger. This will enhance the condensation of toluene vapors with the reduced effluent vapors treated in the packing layers above. The second is to install a separate quench drum to condense the routed toluene vapors more effectively than the existing absorber.
