PDF《国立交通大学》

国立交通大学工学院产业安全与防灾学程 硕士论文批式反应器自主管理技术研究 -以水性压克力树脂制程为例 A Study of Voluntary Protection Program for Batch Reactors -Case Study on Acrylic Resin Process 研究生:刘铭池指导教授 : 陈俊瑜教授 陈俊旖淌 中华民国 九十五 年五月批式反应器自主管理技术研究-以水性压克力树脂制程为例 A Study of Voluntary Protection Program for Batch Reactors -Case Study on Acrylic Resin Process 研究生:刘铭池 Student:Ming-Chih Liu 指导教授:陈俊瑜教授 Advisor:Dr.

Chun-Yu Chen 陈俊旖淌 Dr. Chiun-Hsun Chen 国立交通大学 工学院产业安全与防灾硕士在职专班 硕士论文 A Thesis Submitted to Degree Program of Industrial Safety and Risk Management College of Engineering National Chiao Tung University In Partial Fulfillment of the Requirements for the Degree of Master of Science In Industrial Safety and Risk Management May

2006 Hsinchu, Taiwan, Republic of China 中华民国九十五年五月 i 批式反应器自主管理技术研究-以水性压克力树脂制程为例 研究生:刘铭池 指导教授:陈俊瑜教授、陈俊旖淌 国立交通大学工学院产业安全防灾研究所硕士班 中文摘要 一般的化学工业中,有许多生产制程是以放热反应来进行,在国内采 取批式制程的化学工厂中,其生产制程之反应情形更绝大部分是属於放热 反应,而放热反应的制程若操作不慎,使得反应所产生的热量无法迅速移 除,而导致反应物温度上升,则容易造成「失控反应」,反应制程中若造 成失控反应往往将酿成火灾、爆炸等重大危害,而造成事业单位很大的损 失.民国

85 年桃园县永兴树脂公司发生爆炸、民国

90 年新竹县福国化工 公司之爆炸案,都是因为在生产过程中产生失控反应而造成的重大工安事 件. 本次研究针对压克力树脂制程所用反应原物料以及混合单体反应,进 行个别化学品失控温度评估,以及混合单体反应槽失控后所需之冷却水量 以及冷却槽体体积设计,经过热分析 DSC N温扫描实验以及 C80 恒温卡计 实验后,获得苯乙烯、丙烯酸及丙烯酸丁酯单体与触媒过硫酸钾个别的反 应起始温度为 134.7℃、180.19℃、169.42℃与205.59℃,而混合单体槽 反应物起始反应温度为 80.88℃(82℃恒温约

10 小时),发生失控后反应 温度可达 235.6℃.本研究亦同时经由 VSP2 绝热实验进行混合单体反应槽 失控反应测试,结果发现:绝热失控反应的起始温度在 150℃,一但发生失 控反应,最高温度可达 329℃,最高压力可达 82psig.若采取紧急排放冷 却槽的安全设计,由反应放热量结果可以计算混合单体槽失控后,计需 742.9 kg 冷却水於体积 3.65m3 冷却槽内,进行紧急排放冷却处理. 本次除研究批式反应器於失控反应发生后的紧急排放冷却技术,另针 对批式反应制程进行自主管理研究,藉由t解自主管理系统内涵,建构批 式制程自主管理的政策拟定方法、组织、人员、规划及执行系统,并利用 绩效评量、稽核及管理阶层审查等措施,确认批式反应器操作程序之自主 管理制度与效果.最终研究成果,结合技术及设备面的本质反应危害预防, 以及建构完善的自主管理制度,将此资讯推广至批式反应制程业界,宣导 设计制程本质较安全之紧急排放冷却系统,并提N国内批式制程安全管理 的水平及标准,达到产业降灾目的. 关键字:批式制程、失控反应、紧急排放冷却、自主管理研究 ii A Study of Voluntary Protection Program for Batch Reactors -Case Study on Acrylic Resin Process Student:Ming-Chih Liu Advisor:Dr.Chun-Yu Chen Dr.Chiun-Hsun Chen Degree of Industrial Safety and Risk Management College of Engineering National Chiao Tung University Abstract In chemical industry, many production processes are carried out by exothermic reactions. In Taiwan, exothermic reactions are mostly employed in the production processes for the chemical factories using batch processes. During the exothermic reaction processes, if any careless operation is taken that may cause the difficulty in the immediate removal of reaction heat and bring about an increase of the temperature, then, runaway reaction is prone to occur. Hazards, such as the fire and explosion resulted from the runaway reaction during the reaction processes, are likely to bring substantial damage to the organizations. Accidents like the explosions occurring at Yun Hsin Resin Corp., Taoyuan, 1996, and at Fu Kuo Chemical Industrial Corp., Hsinchu, 2001, were attributed to the runaway reactions that occur during the production processes. This study assesses the runaway onset temperature of individual reactant and the quantity of required quench water and corresponding vessel volume for the mixed monomer reaction in acrylic resin process. The dynamic scanning thermal analysis by DSC and the isothermal experiments by C80 are utilized. To summarize, the onset reaction temperatures of monomers of styrene, acrylic acid, butyl acrylate and catalyst potassium persulfate are obtained as 134.7℃、 180.19℃、169.42℃ and 205.59℃, respectively. In addition, the onset reaction temperature of mixed monomers is 80.88℃(isothermal at 82℃ for 10hrs) and can be reached to the maximum one up to 235.6℃.This study conducts the adiabatic experiments by using VSP2 as well to investigate the runaway iii scenario internal the mixed monomer reactor. Development from the experimental results the adiabatic runaway onset temperature at 150℃ and the maximum temperature and pressure are respectively 329℃ and 82psig. Therefore, it needs 742.9 kg of quench water within a 3.65 m3 of quench vessel to conduct the emergency disposal quench. It is expected that such the strategy information of this study can directly be used by the industry and applied to design an inherently safer emergency disposal system. Besides the emergency venting quench technology, this work also studies the voluntary protection program for the batch process. Based on the understanding of voluntary protection program, this work establishes the planning methods for the strategy, organization, operator, scheme and implement system. In addition, the measures of achieved assessment can be used to inspect, audit and examine the management to confirm the efficiency of voluntary protection program. Eventually, the conclusion of this thesis integrates the inherently hazard prevention technology and equipment and establishes the voluntary protection program that can be applied to reaction process industry popularly. It is wished to preach the inherently safer design of emergency venting quench system and enhance the level and regulation of process safety management in the domestic industry to achieve the goal of lowering the accident rate. Keywords: batch process, runaway reaction, emergency venting quench, voluntary protection program iv 志谢本论文的完成首先感谢陈俊瑜教授、陈俊旖淌,给予细心指导与教 诲,论文口试期间,承蒙胡冠华博士拨冗细审提供宝贵意见,使本论文更 臻完善,同时感谢服务单位行政院劳工委员会北区劳动检查所制造业组所 有同仁在工作上的协助,. 特别感谢在我劳动检查生涯领域中指导我甚多之行政院劳工委员会劳 工检查处吴副处长世雄的提携;