Identifikasi Bahaya pada Unit Karbonasi dengan Metode Hazard and Operability (HAZOP) di Industri Produsen Pupuk

Abstract

The fertilizer manufacturing industry comprises companies engaged in the production of fertilizers and chemicals. One of the fertilizer products produced is ZA fertilizer/Ammonium Sulfate. ZA fertilizer is manufactured through several stages such as carbonation, reaction, filtration, neutralization, evaporation, drying & cooling, and bagging. In the carbonation stage, a reaction occurs between reactants such as NH?, CO?, and water to form ammonium carbonate ((NH?)?CO?), which will then be reacted with gypsum to produce Ammonium Sulfate. Several pieces of equipment are used, such as Chiller E-5103, Carbonation Tower T-5101, Compressor C-5101, pumps, etc. However, this production activity presents potential hazards such as overpressure, overheating, and toxic materials that may be released into the environment, posing risks to workers, environmental pollution, and equipment damage. This study aims to carry out hazard identification and risk assessment using the Hazard and Operability (HAZOP) method based on IEC 61882 standards to identify potential hazards and consequences by combining guidewords and process parameters to detect deviations from normal operating conditions. The HAZOP analysis of the carbonation unit identified total of 151 risks, categorized as follows: 3 extreme risks (1.98%), 18 high risks (11.92%), 105 medium risks (69.53%), and 25 low risks (16.55%) on people, asset, environmental. Some recommendations based on the hazard control hierarchy include adding a Pressure Alarm High (PAH) on Chiller E-5103, implementing a PPM (Predictive, Preventive Maintenance) program, and tagging valves with tag numbers, etc