ANALISIS RISIKO PADA PROSES REFINERY UNIT STRIPPING INDUSTRI BIOETANOL MENGGUNAKAN METODE HAZOP

Abstract

The refinery unit stripping is a critical unit in molasses-based bioethanol production, operating under vacuum conditions at temperatures ranging from 54.51°C to 76.57°C. This unit is susceptible to process failures due to flammable fluids, low-pressure vacuum systems, and instruments prone to fouling from dirty service conditions. This study aims to identify hazards, assess risks, and formulate control recommendations for the refinery unit stripping process using the Hazard and Operability Study (HAZOP) method. The analysis was conducted across 5 study nodes by combining a node-based approach, process parameters, and a 5x5 semi-quantitative risk matrix in accordance with BS IEC 61882 standard. A total of 431 consequences were identified, comprising 229 low risks (53.1%), 193 moderate risks (44.8%), and 9 significant risks (2.1%). The highest significant risks were found in Node 1 (Degassifying Column TW-1702) with a high-level scenario due to FCV-170201 failure potentially causing liquid carry-over to TW-1704, and in Node 5 with spent wash high temperature deviation and ethanol contamination each receiving a risk value of 9. Control recommendations include routine FCV calibration, installation of flammable gas detectors, periodic CIP programs for heat exchanger systems, and real-time monitoring procedures via DCS.