EH2247A

DESIGN PROJECT
MARCH 2019-JULY 2019
PRODUCTION OF 100 000 MTPA OF CUMENE VIA ALKYLATION
OF PROPYLENE AND BENZENE WITH EFFICIENT WASTE TREATMENT
PROCESS

CHAPTER 4: ENVIRONMENTAL AND SAFETY

CONSIDERATION
GROUP MEMBERS
AHMAD FAZLI BIN MOHD GHAZALI 2016728795

MUHAMMAD HAZRY RAFIEQ BIN RAZAK MALEK 2016321741

JAMA’ATUL HASANAH BINTI MD WAZIR 2016354415

HAMZAH HAFIZUDDIN BIN HABRI 2016343911

WAN MUHAMAD ZYAID BIN RAZALI 2016524085

SUPERVISOR
DR. SITI AMINAH MD ALI
FACULTY OF CHEMICAL ENGINEERING
UNIVERSITI TEKNOLOGI MARA
CAWANGAN PULAU PINANG
 AUTHOR’S DECLARATION

“Thereby declare that this report is the result of my own work except for
quotation and summaries which have been duly acknowledge”

AHMAD FAZLI BIN MOHD GHAZALI MUJAMMAD HAZRY RAFIEQ BIN

RAZAK MALEK
2016728795
2016321741

JAMA’ATUL HASANAH BINTI MD HAMZAH HAFIZUDDIN BIN HABRI

WAZIR
2016343911
2016354415

WAN MUHAMAD ZYAID BIN RAZALI

2016524085

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 SUPERVISOR’S CERTIFICATION

“Thereby declare that I have read this thesis and in my opinion this

project report is sufficient in terms of scope and quality for the award

of the Bachelor in Chemical Engineering (Hons).”

Signature : ………………………………………

Name : Dr. Siti Aminah binti Md Ali

Date : ………………………………………

ii
 TABLE OF CONTENT

AUTHOR’S DECLARATION i

SUPERVISOR’S CERTIFICATION ii

TABLE OF CONTENT iii

LIST OF TABLES iv

LIST OF FIGURES v

EXECUTIVE SUMMARY vi

CHAPTER 4 ENVIRONMENTAL AND SAFETY CONSIDERATION 1

4.1 WASTE IDENTIFICATION IN CUMENE PLANT PRODUCTION 1

4.2 WASTE MANAGEMENT 2

4.2.1 Objectives of Environmental and Safety Considerations 3

4.3 RELEVANT LAW, LEGISLATION, REGULATION AND ACT 3

4.3.1 Factory and Machinery Act 1967 3

4.3.2 Occupational Safety and Health Act 1994 4

4.3.3 Environmental Quality Act 1974 7

4.4 WASTEWATER TREATMENT 14

4.5 HAZARD IDENTIFICATION, RISK ASSESSMENT AND RISK CONTROL 15

4.5.1 Hazard identification 16

4.5.2 Likelihood of an occurrence 16

4.5.3 Severity of hazard 17

4.5.4 Risk Assessment 17

4.5.5 HIRARC form 19

4.6 CONCLUSION 24

REFERENCES: 25

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 LIST OF TABLES

Table 4. 1 Indicate Likelihood .................................................................................. 17

Table 4. 2 Severity...................................................... Error! Bookmark not defined.
Table 4. 3 Relative risk priority range.......................... Error! Bookmark not defined.

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 LIST OF FIGURES

Figure 4. 1 Process flow diagram of waste water plant treatment ............................ 14

Figure 4. 2 Flowchart of HIRARC system ................................................................ 16

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 EXECUTIVE SUMMARY

The proposed design to produce 100,000 ton of cumene per annum is via
alkylation of propylene and benzene. Cumene usually produce as a raw material to the
production of acetone and phenol. In alkylation of propylene and benzene, both raw
materials are introduced into a tubular packed bed reactor at a high temperature to
produce cumene. In this process, two flash energy integrated technology was used for
an economically friendly process.

Market analysis is conducted to analyze the marketability of cumene and

propane. This is to ensure that the designed production plant of cumene can compete
with other competitors. Through the market analysis performed, cumene is proven to
be low marketable in Malaysia and therefore need to commercialize abroad. The total
feed cost investment for this process is RM 70,063,799 and the breakeven point is
about 1,765.276 ton.

. Site location to construct the chemical processing plant of cumene is conducted

by analyzing five different potential site locations which are Kerteh and Teluk Kalung
(Terengganu), Gebeng (Pahang), Tanjung Langsat and Pasir Gudang (Johor Bahru).
After analyzing important criteria for selection of site location based on raw material
supply, land price, facilities, utility and availability of labor, Pasir Gudang is selected as
the site location of this plant.

The production of cumene bring huge impact to the environment as it produced

waste that is harmful. To make sure this production process complies to
environmentally friendly type of plant, of this production process to the environment
environmental and safety considerations are analysed and performed with the
compliance with Factory and Machinery Act 1967, Occupational Safety and Health Act
1994 and Environmental Quality Act 1974. All identified wastes are managed, and all
safety measures are taken according to the regulations stipulated in the mentioned
acts.

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 CHAPTER 4

ENVIRONMENTAL AND SAFETY CONSIDERATION

4.1 WASTE IDENTIFICATION IN CUMENE PLANT PRODUCTION

Recently, the importance of environmental and safety issue in chemical

process design has increased rapidly[1]. This is because the growing of world’s
technological and social development has created a high demand for chemicals,
energy, food and commodities[2]. This results in the increase of size and complexity
of chemical processing plants. New hazards and increased risks that are
disadvantageous to the economy and environment are required to be prevented and
mitigated[3]. This situation is also applied to the production of 100,000 tons of cumene
per annum. This is due to cumene plays important roles in petrochemical industry.
such as rubber, iron, steel, paper and paints[4]. Cumene is used primarily about 95 as
an intermediate in the production of phenol and acetone. Other uses include: the
manufacture of styrene, α-methyl styrene, acetophenone, detergents and di-isopropyl
benzene which used as a catalyst for acrylic and polyester-type resins which used as
a thinner for paints while resins which used in printing and rubber manufacture. Minor
amounts are used in gasoline blending and as a component of high-octane aviation
fuel[5]. Cumene is a volatile liquid and exists mainly in the vapour phase in the
atmosphere. It degrades in the atmosphere via reaction with hydroxyl radicals.

Although small amounts of cumene may be removed from the atmosphere by

precipitation, cumene is not expected to react with ozone or directly with light. In water,
cumene can be volatilized, undergo biodegradation, or adsorb to sediments. In soil, it
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is expected to biodegrade rapidly under aerobic conditions. Meanwhile, in water it is
immiscible[6]. By the process of cumene production process it produces a total of
97.91% cumene and the remain 2.09% of it is di-isopropyl benzene (DIPB) act as a
by-product[7]. The amount of this by-product is so little and its low market value
throughout the economic world scene. Because of the two factors stated before, di-
isopropyl benzene (DIPB) will be act as waste in this process. Di-isopropyl benzene
cannot been dump to the environment because its an organic substance and its
immiscible to water. So, this by-product needed to be treated. Furthermore, this
cumene production also have a solid waste from the catalyst and the sludge production
in the wastewater treatment plant. Even though the catalyst ‘zeolite’ is regenerative
catalyst, its lifespan 6 years. This waste must be disposed by following the act or
regulation in term of the schedule waste.

4.2 WASTE MANAGEMENT

Hence, an efficient process safety management mainly under the guidelines

from Factory and Machinery Act (FMA) 1967, Occupational Safety and Health Act
(OSHA) 1994 and Environmental Quality Act (EQA) 1974 is required to ensure that not
only the safety and health of human at the workplace are well protected but also the
environment. It is important to achieve increased inherent safety under the
consideration of environmental safety and health aspects in the initial stage of a
chemical process design that will not only lead to safer, healthier, and more
environmental friendly plant but will also result in reduced overall costs[1].

Waste management is referred to as any activity that involves in the treatment,

disposal and storage of wastes [14]. Waste management for the ethylene production plant
is conducted according to the regulations stipulated in the Environmental Quality Act (EQA)
1974. All solid wastes and wastewater will be managed under EQA 1974. The regulations
stipulated under EQA 1974 that are used in the waste management of this cumene
production plan are as follows:

1. Environmental Quality (Scheduled Wastes) Regulations 2005

2. Environmental Quality (Industrial Effluent) Regulations 2009

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4.2.1 Objectives of Environmental and Safety Considerations

The objectives of the implementation of environmental and safety

considerations are as follows:

1. To ensure a safe and healthy workplace as well as a clean

environment to employees and community.

2. To comply with all relevant and applicable safety and health

laws, regulations, policies, codes and standards.

3. To ensure the production of a high-quality product while

preserving the environment.

4. To ensure an effective hazards identification and control

measures are implemented throughout the workplace.

4.3 RELEVANT LAW, LEGISLATION, REGULATION AND ACT

4.3.1 Factory and Machinery Act 1967

Factory and Machinery Act (FMA) 1967 is referred to as the act that
provides the control of factories with respect to matters that are related to
safety, health and welfare of person therein, the registration and inspection of
machineries and other related matters[8]. The objectives of FMA 1967 are to
control factory operations with respect to safety, health and welfare of persons
and to conduct registration and inspection of machineries. The relevant
regulations for the production plant of cumene are as follows:

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 1. Factories and Machinery (Noise Exposure) Regulations 1989

2. Factories and Machinery (Mineral Dust) Regulations 1989

3. Factories and Machinery (Building Operations and Works of

Engineering Construction (Safety) Regulations 1986

4. Factories and Machinery (Administration) Regulations 1970

5. Factories and Machinery (Notifications of Fitness and

Inspections) Regulations 1970

6. Factories and Machinery (Safety, Health and Welfare)

Regulations 1970

7. Factories and Machinery (Steam Boiler and Unfired Pressure

Vessel) Regulations 1970

4.3.2 Occupational Safety and Health Act 1994

Occupational Safety and Health Act (OSHA) 1994 is defined as the act
that furthers the provisions and welfare of persons at work, protects others
against risks to safety and health related to the activities performed by the
persons at work and to establish the National Council for Occupational Safety
and Health. The concepts of OSHA 1994 include accident prevention as an
essential part of a good management and workmanship, management and
workers must cooperate, and top management must take the lead of
occupational safety and health at the workplace. The list of regulations under
OSHA 1994 is as follow:

1. Occupational Safety and Health (Classification, Labelling and Safety Data

Sheet of Hazardous Chemicals) Regulations 2013[9]
Duty of principal supplier to classify chemical as hazardous chemical
i. Subject to sub-regulation (2), a principal supplier shall classify a
chemical as a hazardous chemical in accordance with the list of
classified chemicals specified in Part 1 of the Industry Code of Practice.

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 ii. If the chemical to be classified is not listed as a classified chemical in
Part 1 of the Industry Code of Practice, the classification of the chemical
as a hazardous chemical shall be in accordance with the physical,
health and environmental hazard of the chemical as specified in Part 2
of the Industry Code of Practice.
2. Occupational Safety and Health (Notification of Accident, Dangerous
Occurrence, Occupational Poisoning and Occupational Disease) Regulations
2004
i. Subject to subsection 1(2) of the Act, these Regulations shall apply to
all places of work.
ii. Nothing in these Regulations shall prejudice any requirement imposed
by or under any other written law relating to reporting of accident,
dangerous occurrence, occupational poisoning or occupational disease

3. Occupational Safety and Health (Use of Standards of Exposure of Chemical

Hazardous to Health) Regulations 2000

Register of chemicals hazardous to health.

i. An employer shall identify and record in a register all chemicals

hazardous to health used in the place of work.

ii. The register shall be maintained in good order and condition and be
updated from time to time and shall contain the following information:

(a) a list of all chemicals hazardous to health used;

(b) the current Chemical Safety Data Sheet for each of the
chemicals hazardous to health except for pesticides which shall
have information as specified in Schedule III

(c) the average quantity used, produced or stored per month or per
year whichever is applicable for each of the chemicals
hazardous to health;

(d) the process and work area where the chemicals hazardous to
health are used; and

(e) the name and address of the supplier of each of the chemicals
hazardous to health.

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 iii. The register shall be accessible to all employees at the place of work
who may be exposed or are likely to be exposed to chemicals
hazardous to health.

iii. The requirements in sub regulations (i) and (ii) shall not apply if the
employer has complied with the requirements of regulation 9 and sub
regulation 11(1) of the Environmental Quality (Scheduled Wastes)
Regulations 1989 [P. U. (A) 139/89]

4. Occupational safety and Health (Safety and Health Officer) Regulations 1997

Appointment of officers.

i. The Minister shall appoint a public officer to be the Director General of

Occupational Safety and Health, in this Act referred to as the “Director
General”, for the purpose of exercising the powers, performing the
functions and discharging the duties assigned to him under this Act.
ii. The Minister may appoint, from among public officers, such numbers of
Deputy Directors General, Directors, Deputy Directors, Assistant
Directors and other occupational safety and health officers as may be
necessary for the purposes of this Act.
iii. If for any reason the Director General is unable to exercise the powers
or discharge the duties of his office, the power shall be had and may be
exercised and the duties shall be discharged by the Deputy Director
General.

5. Occupational Safety and Health (Safety and Health Committee) Regulations

1996

Application.

i. These Regulations shall apply to a safety and health committee

established under section 30 of the Act.
ii. A safety and health committee formed at a place of work before the
commencement of these Regulations shall reorganise itself in
accordance with these Regulations within six months from the date of
the commencement of these Regulations.

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 6. Occupational Safety and Health (Control of Industrial Major Accident Hazards)
Regulations 1996

Identification and notification

i. Every manufacturer shall-

a) identify an industrial activity within his control
b) submit to the Director General the Notification of Industrial Activity
Form (hereinafter referred to as the "Notification") specified in
Schedule 5

4.3.3 Environmental Quality Act 1974

Environmental Quality Act (EQA) 1974 is an act established to prevent, abate, control
pollution and enhance the environment, and for any related purposes[10]. EQA 1974
restricts the wastes discharge into the environment according to the acceptable
conditions[11]. The relevant regulations of EQA 1974 for the chemical plant of the
production of ethylene are as follows[11]:

Environmental Quality (Licensing) Regulations 1977

Environmental Quality (Prescribed Activities) (Environmental Impact Assessment)

Order 1987

Industry

Chemicals - where production capacity of each product or of combined products

is greater than 100 tonnes/day

Petrochemicals - all size

Shipyards – production capacity greater than 50 tonnes/day

Transportation

Construction of Mass Rapid Transport projects.

Waste treatment and disposal

1) Toxic and Hazardous Waste:

(i) Construction of incineration plant.

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 (ii) Construction of recovery plant (off - site).

(iii) Construction of wastewater treatment plant (off-site).

(iv) Construction of secure landfill facility.

(v) Construction of storage facility (off - site)

2) Municipal Solid Waste:

(i) Construction of composting plant.

(ii) Construction of recovery/recycling plant..

(3) Municipal Sewage:

(i) Construction of wastewater treatment plant

(ii) Construction of marine outfall.

Environmental Quality (Scheduled Wastes) Regulations 2005

3.Notification of the generation of scheduled wastes

(1) Every waste generator shall, within 30 days from the date of generation of
scheduled wastes, notify the Director General of the new categories and quantities of
scheduled wastes which are generated.

(2) The notification given under sub regulation (1) shall include the information
provided in the Second Schedule.

4. Disposal of scheduled wastes

(1) Scheduled wastes shall be disposed of at prescribed premises only.

(2) Scheduled wastes shall, as far as is practicable, be rendered innocuous prior to

disposal.

5. Treatment of scheduled wastes

(1) Scheduled wastes shall be treated at prescribed premises or at on-site treatment

facilities only.

(2) Residuals from treatment of scheduled wastes shall be treated or disposed of at

prescribed premises.

6. Recovery of material or product from scheduled wastes

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(1)Recovery of material or product from scheduled wastes shall be done at prescribed
premises or at on-site recovery facilities.

(2) Residuals from recovery of material or product from scheduled wastes shall be
treated or disposed of at prescribed premises.

7. Application for special management of scheduled wastes

(1) A waste generator may apply to the Director General in writing to have the
scheduled wastes generated from their particular facility or process excluded from
being treated, disposed of or recovered in premises or facilities other than at the
prescribed premises or on-site treatment or recovery facilities.

(2) An application under sub regulation (1) shall be submitted to the Director General
in accordance with the guidelines for special management of scheduled wastes as
prescribed by the Director General and shall be accompanied by fee of three hundred
ringgit and shall not be refunded.

(3) If the Director General is satisfied with the application made under sub
regulation(1), the Director General may grant a written approval either with or without
conditions.

8. Responsibility of waste generator

(1) Every waste generator shall ensure that scheduled wastes generated by him are
properly stored, treated on-site, recovered on-site for material or product from such
scheduled wastes or delivered to and received at prescribed premises for treatment,
disposal or recovery of material or product from scheduled wastes.

(2) Every waste generator shall ensure that scheduled wastes that are subjected to
movement or transfer be packaged, labelled and transported in accordance with the
guidelines prescribed by the Director General.

9. Storage of scheduled wastes

(1) Scheduled wastes shall be stored in containers which are compatible with the
scheduled wastes to be stored, durable and which are able to prevent spillage or
leakage of the scheduled wastes into the environment.

(2) Incompatible scheduled wastes shall be stored in separate containers, and such
containers shall be placed in separate secondary containment areas.

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(3) Containers containing scheduled wastes shall always be closed during storage
except when it is necessary to add or remove the scheduled wastes.

(4) Areas for the storage of the containers shall be designed, constructed and
maintained adequately in accordance with the guidelines prescribed by the Director
General to prevent spillage or leakage of scheduled wastes into the environment.

(5) Any person may store scheduled wastes generated by him for 180 days or less
after its generation provided that:

a) the quantity of scheduled wastes accumulated on site shall not exceed 20

metric tonnes; and

b) the Director General may at any time, direct the waste generator to send any
scheduled wastes for treatment, disposal or recovery of material or product from the
scheduled wastes up to such quantity as he deems necessary.

(6) A waste generator may apply to the Director General in writing to store more than

20 metric tonnes of scheduled wastes.

(7) If the Director General is satisfied with the application made under subregulation(6),
the Director General may grant a written approval either with or without conditions.

10. Labelling of scheduled wastes

(1) The date when the scheduled wastes are first generated, name, address and
telephone number of the waste generator shall be clearly labelled on the containers
that are used to store the scheduled wastes.

(2) Containers of scheduled wastes shall be clearly labelled in accordance with the
types applicable to them as specified in the Third Schedule and marked with the
scheduled waste code as specified in the First Schedule for identification and warning
purposes.

11. Waste generator shall keep an inventory of scheduled wastes A waste generator
shall keep accurate and up-to-date inventory in accordance with the Fifth Schedule of
the categories and quantities of scheduled wastes being generated, treated and
disposed of and of materials or product recovered from such scheduled wastes for a
period up to three years from the date the scheduled wastes was generated.

12. Information to be provided by waste generator, contractor and occupier of

prescribed premises
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(1) A waste generator, contractor and occupier of the prescribed premises shall provide
information in accordance with the Sixth Schedule in the manner provided in this
regulation or Director General shall determine other method as he thinks fit.

(2) A waste generator shall complete Part I of the Sixth Schedule in six copies and
hand over the six copies of the Schedule to the contractor when the scheduled wastes
are delivered to him.

13. Scheduled wastes transported outside waste generator's premises to be

accompanied by information

(1) Every waste generator shall provide information in accordance with the Seventh
Schedule in respect of each category of scheduled wastes to be delivered to the
contractor and shall give the Schedule to the contractor upon delivery of the waste to
him.

(2) The waste generator shall inform the contractor of the purpose and use of the
Seventh Schedule.

(3) The contractor shall carry with him the Seventh Schedule for each category of
scheduled wastes being transported and shall observe and comply with the
instructions contained therein

14. Spill or accidental discharge

(1) In the event of any spill or accidental discharge of any scheduled wastes, the
contractor responsible for the waste shall immediately inform the Director General of
the occurrence.

(2) The contractor shall do everything that is practicable to contain, cleanse or abate
the spill or accidental discharge and to recover substances involved in the spill or
accidental discharge

15. Conduct of training Every waste generator shall ensure that all his employees
involved in the identification, handling, labelling, transportation, storage and spillage or
discharge response of scheduled wastes attend training programmes.

16. Compounding of offences

(1) Every offence which consists of any omission or neglect to comply with, or any act
done or attempted to be done contrary to these Regulations may be compounded
under section 45 of the Act.

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(2) The compounding of offences referred to in sub regulation (1) shall be in
accordance with the procedure prescribed in the Environmental Quality (Compounding
of Offences) Rules 1978 [P.U. (A) 281/1978]

Environmental Quality (Industrial Effluent) Regulations 2009

The regulations are under Third Schedule, Regulation 8(1), 8(2) & 8(3) in which the
limit for the parameter given in a table. There are two standard that have to be complied
which is Standard (A) and Standard (B). The regulations are applied to monitor and
control the quality of the waste water treatment facility to make sure that the waste
water that will be discharged to the environment is within the limit that will not harm the
environment. The list of the parameter and the limit that have to be followed are listed
showed in table 4.1.

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 FIFTH SCHEDULE
[Paragraph 11(1)(a)]
ACCEPTABLE CONDITIONS FOR DISCHARGE OF INDUSTRIAL
EFFLUENT OR MIXED EFFLUENT OF STANDARDS A AND B

Table 4. 1 Parameter and the limit

Parameter Unit Standard

A B
(1) (2) (3) (4)
o
(i) Temperature C 40 40
(ii) pH Value - 6.0-9.0 5.5-
9.0
(iii) BOD at 20oC mg/L 20 50
(iv) Suspended mg/L 50 100
Solids
(v) Mercury mg/L 0.005 0.05
(vi) Cadmium mg/L 0.01 0.02
(vii) Chromium, mg/L 0.05 0.05
Hexavalent
(viii) Chromium, mg/L 0.20 1.0
Trivalent
(ix) Arsenic mg/L 0.05 0.10
(x) Cyanide mg/L 0.05 0.10
(xi) Lead mg/L 0.10 0.5
(xii) Copper mg/L 0.20 1.0
(xiii) Manganese mg/L 0.20 1.0
(xiv) Nickel mg/L 0.20 1.0
(xv) Tin mg/L 0.20 1.0
(xvi) Zinc mg/L 2.0 2.0
(xvii) Boron mg/L 1.0 4.0
(xviii) Iron (Fe) mg/L 1.0 5.0
(xix) Silver mg/L 0.1 1.0
(xx) Aluminium mg/L 10 15
(xxi) Selenium mg/L 0.02 0.5
(xxii) Barium mg/L 1.0 2.0
(xxiii) Fluoride mg/L 2.0 5.0
(xxiv) Formaldehyde mg/L 1.0 2.0
(xxv) Phenol mg/L 0.001 1.0
(xxvi) Free Chlorine mg/L 1.0 2.0
(xxvii) Sulphide mg/L 0.50 0.50
(xxviii) Oil and Grease mg/L 1.0 10
(xxix) Ammoniacal mg/L 10 20
Nitrogen
(xxx) Colour ADMI* 100 200

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4.4 WASTEWATER TREATMENT

Wastewater
influent STORAGE TANK
EFFLUENT

COAGULATION TANK FLOCULATION

PRIMARY CLARIFIER

CENTRIFUGAL THICKENING

Figure 4. 1 Process flow diagram of waste water plant treatment

With industrial development, there is increase in the amount of oil used, but
various technical and management developments lag behind other reasons that are
not perfect and make a lot of oil into the water, forming pollution. Treating oily
wastewater sources is very broad, as the oil in the oil industry, oil refining, oil storage,
transportation and petrochemical industries in the production process generate lot of
oily wastewater. The process of cumene production release a little amount of waste
that contain di-isopropyl benzene. Di-isopropyl benzene is a by-product of cumene
process only few of it produces. Its immiscible in water so the characteristic of this
waste is same as oil. The wastewater treatment plant involve coagulation, flocculation
sedimentation and sludge process.

Figure 4.1 shows the waste water treatment plant process in the cumene
production plant. All of this process is in physical and chemical treatment. The
wastewater treatment process started with the effluent came out of the plant. The
wastewater influent is store in a close tank due to low effluent. After that, the
wastewater undergoes coagulation process in the coagulation tank with adding the
coagulant agent. among other treatment to treat waste, coagulation is the most
effective and economically to treat di-isopropyl benzene. According to, Li Yu (2013) for
the treatment of oily wastewater oil industry has developed a composite coagulant
CAX, when the original oil in water concentration was 207 mg/L, COD concentration
was 600 mg/L, after coagulation treatment, oil and COD removal efficiency reached
98% and 80% respectively using aggregation zinc silicate (PISS) and anionic
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polyacrylamide (A-PAM) composite flocculant oily wastewater treatment, improved oil
removal efficiency up to 99%, suspended solids concentration was less than 5 mg/L,
and met back water requirements[12]. For enhancing the floc, the flocculation process
in the flocculation tank is added. The suspended solid from the process is sedimented
by the clarifier and the suspended solid is settled down to the sludge dewatering
process. The sludge is been dispose in a suitable dispose area.

4.5 HAZARD IDENTIFICATION, RISK ASSESSMENT AND RISK CONTROL

Hazard is known as the any source of potential damage, harm or adverse

health effects on something or someone. Hazard must be identified as there is risk on
all type of hazard that be identify. It follows the hazard identification, Risk Assessment
and Risk Control (HIRARC) that this HIRARC is practice of planning, management and
the operation of a business as a basic of risk management. A hazard identification and
risk assessment are processes used to identify and evaluate both existing and
potential hazards on a worksite and the methods used to control or eliminate the
hazards identified. The organizations that have carried out risk assessment at the work
place have noted numerous changes in their working practice. Those who have
already carried out risk assessment in their work, have reported positive changes in
their working practice, they recognize substandard act and working condition as they
develop and take necessary corrective action[13]. Figure 4.2 shows the flowchart of
the HIRARC system where its require four simple steps that is classify work activities,
identify hazard, conduct risk assessment and decide if risk is tolerable and apply
control measures.

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 Figure 4. 2 Flowchart of HIRARC system

4.5.1 Hazard identification

Hazard is defined as anything (e.g. condition, situation, practice, behaviour)

that has the potential to cause harm, including injury, disease, death, environmental,
property and equipment damage. Hazard can be identified throughout many
perspective and identification method such as the employee implemented that all of
their work is hazardous to them. There many types of hazard inside of a workplace
including a small thing I could be a hazardous to people such as chemical and many
other else. This is the process of examining each work area and work task for the
purpose of identifying all the hazards which are “inherent in the job”.

4.5.2 Likelihood of an occurrence

This value is based on the likelihood of an event occurring. You may ask the
question “How many times has this event happened in the past?” Assessing likelihood
is based worker experience, analysis or measurement. From the table 4.1 it indicates
the likelihood of an occurrence. Likelihood levels range from “most likely” to
“inconceivable.” The rate of the likelihood is from 1 to 5. For example, a small spill of
bleach from a container when filling a spray bottle is most likely to occur during every
shift. Alternatively, a leak of diesel fuel from a secure holding tank may be less
probable[14]. From the table 4.2 it shows that the rating of the likelihood is at 5.

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 Table 4. 2 Indicate Likelihood

LIKELIHOOD(L) EXAMPLE RATING

Most likely The most likely result of the hazard / event being 5
realized

Possible Has a good chance of occurring and is not unusual 4

Conceivable Might be occur at sometimes in future 3

Remote Has not been known to occur after many years 2

Inconceivable Is practically impossible and has never occurred 1

4.5.3 Severity of hazard

Severity can be divided into five categories. Severity are based upon an
increasing level of severity to an individual’s health, the environment, or to property[14].
Table 4.3 indicates severity by using the following table:

Table 4. 3 Severity

SEVERITY EXAMPLE RATING

Catastrophic Numerous fatalities, irrecoverable property damage 5
and productivity
Fatal Approximately one single fatality major property 4
damage if hazard is realized
Serious Non-fatal injury, permanent disability 3
Minor Disabling but not permanent injury 2
Negligible Minor abrasions, bruises, cuts, first aid type injury 1

4.5.4 Risk Assessment

Hazard is closed relationship with the risk. Risk is a measurement to analyse

and evaluate the hazard [14]. The measurement is made by identification on how
severe and when likely of the hazard. In other words, the risk assessment is an in-
depth look to specify situations, process and other harmful activities or hazard at
workplace. Risk is presented in variety of ways to communicate the distribution of the

17
risk throughout a plant and area in a workplace. The results of risk assessment that
presented in a risk matrix are essential to make decision on risk control[13]. Risk is the
combination of the likelihood and severity of a specified hazardous event occurring. In
mathematical term, risk can be calculated by the equation:

Risk = Likelihood x Severity

From the equation, it shows that the likelihood is an event likely to occur within
the specific period or in specified circumstances and severity is outcome from an event
such as severity of injury or health of people, or damage to property, or insult to
environment, or any combination of those caused by the event[14]. The relative risk
value can be used to prioritize necessary actions to effectively manage work place
hazards. Table 4.4 determines priority based on the following ranges:

Table 4. 4 Relative risk priority range

RISK DESCRIPTION ACTION

15-25 HIGH A HIGH risk requires immediate action to control the
hazard as detailed in the hierarchy of control.
Actions taken must be documented on the risk
assessment form including date for completion
5-12 MEDIUM A MEDIUM risk requires a planned approach to
controlling the hazard and applies temporary
measure if required. Actions taken must be
documented on the risk assessment form including
date for completion.
1-4 LOW A risk identified as LOW may be considered as
acceptable and further reduction may not be
necessary. However, if the risk can be resolved
quickly and efficiently, control measures should be
implemented and recorded.

18
4.5.5 HIRARC form

PIC due
Exciting Risk Likelih Severi Recommended control
No Chemical Hazard Cause/Effect Risk date
Control ood ty measure
status
Extremely Eye: Causes eye irritation. Spills/Leaks: Abs Engineering Controls: Use
flammable liquid Skin: Causes skin irritation. Harmful if absorbed through orb spill with inert stringent control measures
and vapor. Vapor the skin. Prolonged and/or repeated contact may cause material (e.g. such as process enclosure to
may cause flash defatting of the skin and dermatitis. vermiculite, sand prevent product release into
fire. Harmful if Ingestion: May cause central nervous system or earth), then the workplace. Use backup
swallowed, depression, characterized by excitement, followed by place in suitable controls (e.g. double
inhaled, or headache, dizziness, drowsiness, and nausea. Advanced container. mechanical pump seals) to
absorbed through stages may cause collapse, unconsciousness, coma and prevent the release of this
the skin. Causes possible death due to respiratory failure. May cause material due to equipment
eye, skin, and effects similar to those for inhalation exposure. Aspiration failure. Use non-sparking
1 benzene 5 3 15
respiratory tract of material into the lungs may cause chemical ventilation systems, approved
irritation. Contains pneumonitis, which may be fatal. explosion-proof equipment
benzene. Benzene Inhalation: Causes respiratory tract irritation. May cause and intrinsically safe electrical
can cause cancer. drowsiness, unconsciousness, and central nervous systems in areas where this
Aspiration hazard system depression. Exposure may lead to irreversible product is used and stored
if swallowed. Can bone marrow injury. Exposure may lead to aplastic
enter lungs and anaemia. Potential symptoms of overexposure by
cause damage. inhalation are dizziness, headache, vomiting, visual
May cause blood disturbances, staggering gait, hilarity, fatigue, and other
abnormalities. May symptoms of CNS depression.

19
 cause central Chronic: May cause bone marrow abnormalities with
nervous system damage to blood forming tissues. May cause anaemia
effects. and other blood cell abnormalities. Chronic exposure to
benzene has been associated with an increased incidence
of leukaemia and multiple myeloma (tumour composed of
cells of the type normally found in the bone marrow).
Immunoexpressed effects have been reported. This
substance has caused adverse reproductive and fatal
effects in laboratory animals.
Extremely Spill or Leak
flammable gas Inhalation Risk: On loss of containment this gas can cause Eliminate all
Contains gas suffocation by lowering the oxygen content of the air in ignition sources
under pressure; confined areas. Vapor concentrations above recommended (no smoking,
may explode if exposure levels are irritating to the eyes and the respiratory flares, sparks or
heated tract, may cause headaches and dizziness, are anaesthetic flames in
Vapours may and may have other central nervous system effects. Causes immediate area). Engineering Controls
cause drowsiness suffocation (asphyxiant) if allowed to accumulate to All equipment The use of local exhaust
or dizziness concentrations that reduce oxygen below safe breathing used when ventilation is recommended to
levels. Effects of Short-Term Exposure: Rapid evaporation handling the control emissions near the
of the liquid may cause frostbite. The substance may cause product must be source. Laboratory samples
2 propylene 5 4 20
effects on the central nervous system. Exposure could grounded. Do not should be handled in a fume
cause lowering of consciousness. touch or walk hood. Provide mechanical
Eye Contact: Exposure to rapidly expanding gas or through spilled ventilation of confined spaces.
vaporizing liquids may cause frostbite (cold burns) or tissue material. Stop leak Use explosion-proof ventilation
damage. if you can do it equipment
Skin Contact: Exposure to rapidly expanding gas or without risk. If
vaporizing liquid may cause frostbite (cold burn). In case of possible, turn
frostbite, place affected area in warm water until circulation leaking containers
returns. so that gas
Ingestion: Not considered to be a hazard. escapes rather
than liquid.

20
 Flammable liquid Inhalation May be harmful if inhaled. Causes respiratory Spill or leak Engineering controls: Use
and vapor tract irritation. Methods and engineering controls to
Harmful if Skin May be harmful if absorbed through skin. Causes skin materials for maintain airborne level below
swallowed irritation. containment and exposure limit requirements or
Causes skin Eyes Causes eye irritation. cleaning up guidelines. If there are no
irritation Ingestion May be harmful if swallowed. Aspiration hazard Contain spillage, applicable exposure limit
Causes eye if swallowed - can enter lungs and cause damage. and then collect requirements or guidelines,
irritation with an electrically use only with adequate
Suspected of protected vacuum ventilation. Local exhaust
causing cancer cleaner or by wet- ventilation may be necessary
May cause brushing and for some operations.
respiratory place in container Individual protection
irritation for disposal measures
according to local Eye/face protection: Use
Isopropyl regulations (see safety glasses (with side
3 benzene section 13). 2 3 6 shields). If exposure causes
(cumene) eye discomfort, use a full-face
respirator
Skin protection Hand
protection: Use gloves
chemically resistant to this
material when prolonged or
frequently repeated contact
could occur.
Respiratory protection:
Respiratory protection should
be worn when there is a
potential to exceed the
exposure limit requirements or
guidelines.

21
 Combustible liquid Causes skin irritation Causes serious eye irritation May Contain spillage, Engineering Measures
Causes skin cause respiratory irritation soak up with non- Ensure that eyewash stations
irritation Causes combustible and safety showers are close
serious eye absorbent to the workstation location.
irritation May material, (e.g. Ensure adequate ventilation,
cause respiratory sand, earth, especially in confined areas.
irritation diatomaceous Use explosion-proof
earth, vermiculite) electrical/ventilating/lighting/e
De-
and transfer to a quipment.
isopropylb
4 container for 1 3 3
enzen
disposal according
(DIPB)
to local / national
regulations (see
section 13). After
cleaning, flush
away traces with
water. Eliminate all
ignition sources if
safe to do so.
Extremely Eyes Direct contact with liquid propane can result in eye Recovery and Engineering Measures Use
flammable gas. burns Neutralization Stop adequate ventilation to keep
Contains gas Skin Direct contact with liquid propane can result in skin the source of the gas and vapor concentrations
under pressure, burns (frostbite). release, if safe to of this product below
may explode if Ingestion Risk of ingestion is extremely low. However, if do so. Materials occupational exposure and
5 propane 3 2 6
heated. oral exposure occurs, seek immediate medical assistance and Methods for flammability limits, particularly
Inhalation This product is classified as a simple asphyxiant. Clean-Up in confined spaces. Use
High vapor concentrations may produce a reversible central Do not flush down explosion-proof equipment
nervous system depression (anesthesia) and asphyxiation. sewer or drainage and lighting in
systems. Do not classified/controlled areas.

22
 touch spilled liquid
(frostbite/freeze
burn hazard!).
Consider the use
of water spray to
disperse vapors.
Isolate the area
until gas has
dispersed.

23
4.6 CONCLUSION

In conclusion, the environmental and safety consideration chapter consist of

waste identification, waste management based on waste of the production, safety
legislation and Hazard identification, Risk Assessment and Risk Control (HIRARC).
The waste identifies as di-isopropyl benzene as an organic compound produce from
cumene production plant. It treated as waste water in waste water treatment plant
specifically for this waste effluent. Throughout the process of waste treatment, the
waste management is practically important for no endangered the environment by
releasing or discharging freely with harmful substance. The related safety legislation
discussed for the development of this plant are Occupational Safety and Health
(OSHA) 1974 and The Factory and Machinery Act (FMA) 1967. This legislation is
prioritized as the production plant follow it with no objection. Lastly, in Hazard
Identification, Risk Assessment and Risk Control (HIRARC), the chemical that involved
in this production is propylene, benzene, propane and di-isopropyl benzene. By the
HIRARC process it can be determined the risk and the severity of the chemical
throughout the whole processing of this cumene production plant.

24
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[13] A.C. Ahmad, I.N. Mohd Zin, M.K. Othman, N.H. Muhamad, Hazard
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