Safety Evaluation Report of Dafeng Yuntao Biotechnology Co., Ltd.
Time：2021-07-21
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1. Name of safety assessment project:
Dafeng Yuntao Biotechnology Co., Ltd. 3750t/a p-hydroxyphenylglycine, 4000t/a p-hydroxyphenylglycine Deng potassium salt and 1000t/a camphor sulfonic acid production project general layout, process, equipment and storage adjustment special project safety evaluation report
2. Introduction to the safety assessment project:
Founded on May 28, 2003, Dafeng Yuntao is located in Yancheng Dafeng Port Petrochemical New Materials Industrial Park, covering an area of 119995m2, registered by Yancheng Dafeng District Market Supervision and Administration Bureau (unified social credit code 91320982750034082K), registered capital 200 million yuan, the existing staff of 96 people, 3 full-time safety management personnel.
Dafeng Yuntao has 3750t/a p-hydroxyphenylglycine, 4000t/a p-hydroxyphenylglycine Deng potassium salt, and 1000t/a camphor sulfonic acid projects, all of which have passed the completion acceptance. According to Article 2 of the "Measures for the Implementation of Safety Production Licenses for Hazardous Chemical Production Enterprises" (Order No. 41 of the State Administration of Work Safety), Dafeng Yuntao's existing project products are not hazardous chemicals, and no hazardous chemical products are generated during the production process of the construction project, which is not a hazardous chemical construction project. No safety production license is required.
Dafeng Yuntao 4000t/a p-hydroxyphenylglycine Deng potassium salt, 3750t/a p-hydroxyphenylglycine project and 1000t/a camphor sulfonic acid project After several years of operation, combined with automation transformation, some auxiliary processes, equipment, general layout and material storage are now optimized and adjusted. The details are as follows:
Description of the optimization and adjustment of the general layout; Dafeng Yuntao's adjustment of no new buildings in this period does not involve changes in the building structure and fire risk level of the building.
Second, process adjustment:
1. P-Hydroxyphenylglycine Production Project (Workshop 1 and 2):
(1) Decolorization and adsorption treatment steps are added in the preparation of synthetic mixed phenylglycine: the mother liquor in the mother liquor collection tank is decolorized to the resin tower, and the resin in the decolorizing resin tower completely adsorbs the pigment in the centrifugal mother liquor. After the decolorizing resin tower treatment, the decolorizing liquid is pumped into the adsorption resin tower for treatment. The resin in the adsorption resin tower completely adsorbs o-hydroxyphenylglycine and a small amount of residual p-hydroxyphenylglycine. The adsorption liquid is ammonium sulfate aqueous solution, which is colorless or light yellow clear liquid. Temporarily stored in the transit storage tank.
(2) During the preparation of racemic dextrose double salt, the original process is to heat up to 102-105 ° C to reflux for about 20 hours for racemic, and steam out benzaldehyde in the solution. After the change, there is no need to heat up to 102-105 ° C, just keep warm for 20 hours, let it stand and layer, and the lower benzaldehyde can be separated and recycled. The process is simplified and the safety is higher.
(3) In the preparation process of racemic dextral double salt, the original process is that the centrifugal mother liquor is first concentrated and dehydrated in the concentration kettle, and then decolorized. After the change, the concentration, dehydration and decolorization are carried out in the decolorization kettle (R0201A~ C). This shortens the process flow, improves the process safety, and also meets the requirements of energy reduction and consumption reduction.
2. P-Hydroxyphenylglycine Deng Potassium Salt Production Project (Three Workshops):
(1) During the synthesis process, the first 8 synthetic reactors (R2001a-h) were heated with hot water, the adjusted 7 were synthetic reactors (R2001a-c, e-h), which were heated with steam, and 1 was changed to a cooling crystallization reactors (R2001d). Adjustment reasons: The use of hot water heating requires a hot water reservoir and a hot water pump. Once the hot water pump fails, production must be suspended, and precise temperature control devices must be added. Equipment and labor have exceeded the cost of steam. After changing to steam heating, the corresponding steam emergency cut-off and adjustment functions and the interlocking of temperature and steam cut-off in the kettle are added. Once the steam regulating valve exceeds 70 ° C, it will automatically adjust until the emergency cut-off (75 ° C) steam valve, and when the reaction temperature of the synthetic kettle is 75 ° C, the interlocking cuts off the steam valve, so the hot water is changed to steam heating, and its safety is controllable. In addition, in order to solve product quality problems and prolong the cooling crystallization time, the synthetic kettle is changed to a cooling crystallization kettle.
(2) In the synthesis process, the original synthesis section process description "During the continuous distillation process, new methanol is continuously added to the synthesis kettle (R2001a~ h) through the methanol high-level tank (V2001ab, V2002ab) to keep the total methanol in the synthesis kettle (R2001a~ h) basically unchanged". After recent process optimization, it is no longer necessary to continuously replenish methanol, but to pump quantitative methanol in the synthesis kettle at one time to meet the process needs. Therefore, this process description can be deleted.
III. Equipment and equipment layout adjustments
1. P-Hydroxyphenylglycine Production Project (Workshop 1 and 2):
(1) Adjustment of workshop equipment
1) During the preparation of synthetic mixed phenylglycine: add decolorization tower, adsorption tower, filter press, transfer pump, and process water pump.
2) In the decolorization, filtration, and neutralization section, due to the improvement of product quality, no decolorization operation is required to meet the neutralization requirements. Therefore, the left double salt products enter the neutralization kettle for neutralization without decolorization through the R0110 kettle. Therefore, the original function of the decolorization kettle R0110 can be omitted and changed to a sulfuric acid overflow receiving tank; the corresponding filter X0103 is removed.
3) The original centrifuge M0105A/B (upper discharge) in the refined left salt section was discontinued and replaced by M0104A-F centrifuge. Due to the long intermittent operation time, these six centrifuges can meet production needs.
4) Due to the fact that the tap water used in the refining and neutralization positions cannot meet the process requirements, a plate and frame filter (X0105) is required.
5) Added a new 10000L emergency receiving tank (V0126).
(2) Adjustment of workshop equipment
The water content in the material is too large, and it needs to be evaporated in the splitting kettle first, so 18 condensers (E0202~ E0207, E0214~ E0219, E0226~ E0231) are added on the third floor of the workshop.
2) During the preparation of racemic dextran double salt: 3 concentrators (R0240A~ C) were removed.
3) Since the centrifuge discharge method was changed, the efficiency was greatly improved, so six M0201 (I, J, G, H, K, L) centrifuges were reduced and dismantled.
4) Due to the damage of the splitting kettle (R0237) jacket, the remaining splitting kettle can also meet the production needs.
5) Add two 10000L explosion venting tanks (V0208, 0209).
2. P-Hydroxyphenylglycine Deng Potassium Salt Production Project (Three Workshops):
(1) Synthesis process The original 8 synthesis kettles (R2001a-h) are now changed to 7 synthesis kettles (R2001a-g), and the original 4 crystallization kettles (R2002a-d) are now changed to 5 crystallization kettles (R2002a-e).
(2) The original decompression recovery methanol exhaust port had three condensers (E2002a, b, c), and two (E2002b, c) were removed.
(3) Due to market reasons, only one-third of the project's production capacity has been insufficient for a long time, so the crude alcohol tank V2015B and the refined methanol receiving tank V2017B that have been idle for a long time will be removed.
(4) In order to avoid the problem of sticking to both sides of the power distribution room, the cooling kettle (R2006) on the south side of the first floor was moved to the west side of the new partition wall, and the door was opened on the west side; the four methanol high-level troughs (V2001a, b, V2002a, b) on the south side of the second floor were moved to the west side of the new partition wall.
3. Camphor sulfonic acid production project (four workshops):
(1) Due to the high viscosity of the left camphor stock solution and the slow speed of passing through the column, an ion exchange column T4301E is added.
(2) Explosion-proof walls are installed on the first to second floors of the stairwell on the south side of the power distribution room and the production plant on the west side, and evacuation exits are installed on the south side.
(3) Add a 10000L emergency receiving tank (V4802).
3. Safety evaluation project leader, technical leader, process control leader, evaluation report compiler, report auditor, safety evaluator, registered safety engineer, and technical expert involved in the evaluation:
Safety evaluation project leader: Gao Weili
Technical person in charge: Zhou Junhong
Person in charge of process control: Sun Guang
Evaluation Report Compilers: Gao Weili, Zhao Yun, Ma Junxing
Report Reviewer: Zhang Tongzhong
Safety evaluators, registered safety engineers, and technical experts participating in the evaluation work: Gao Weili, Yang Jiangming, Ma Junxing, Sun Guang, Zhou Junhong, etc
4. Time and main tasks for conducting safety evaluation work on site, and evaluation report time:
In June 2020, Dafeng Yuntao Biotechnology Co., Ltd. approached Hebei Huafei Technology Consulting Co., Ltd. (hereinafter referred to as "Huafei Company") to discuss its 3750t/a p-hydroxyphenylglycine, 4000t/a p-hydroxyphenylglycine Dunkali salt and 1000t/a camphor sulfonic acid production project general layout, process, equipment and storage adjustment special project safety evaluation work. Huafei Company assigned relevant personnel to Dafeng Yuntao Biotechnology Co., Ltd. to conduct on-site inspections to understand the main equipment and processes of the project, the general layout and other changes, and collected relevant information of the project, and made relevant risk analysis of the project. After many conferrals, the relevant personnel of the two companies formed a preliminary intention and initially clarified the object and scope of the evaluation.
During the evaluation process, the members of the evaluation team carefully analyzed and sorted out the relevant materials provided by the enterprise and collected on site, identified the dangerous and harmful factors existing in the project, conducted a qualitative and quantitative evaluation of the inherent danger degree of the project according to the divided evaluation units, and analyzed the risk degree of the project, put forward targeted safety countermeasures and suggestions, and exchanged views with the construction unit, and made a safety evaluation conclusion on this basis. After solid work, the special project safety evaluation report of the project was completed in September 2020 and verified by the expert group.