Assessment task description
Unit learning outcomes addressed:
• Perform Hazard Identification
• Carry out a Hazard and Operability study.
• Work through a P&ID diagram, design of safety systems
• Understand an Environmental Management System
• Perform Environmental Impact Assessments
• Quantitatively predict the effect of a process on the environment.
Overview
This task evaluates your understanding of the process of
identification, assessment and control of safety and environmental hazards.
You are a Process Engineer with company Ethanol QED proposing to construct a new distillery adjoining the Rocky Point sugar factory 50 km south of Brisbane(this
located in QLD). The distillery will use steam from a previously mothballed low pressure boiler and there will be a new bulk storage of final molasses on site. New
adjacent land will need to be purchased and approved to fit the new plant. It is currently planned that the distillery will use conventional technology to produce 30
Mega litres of ethanol per year. Additional sources of molasses will be required which will be delivered using road transport from other suppliers.
There is a fed batch process involved in which a fermentation tank is supplied with yeast and diluted molasses and is converted to dilute ethanol and other products,
with carbon dioxide being exhausted from the tank. Temperature control is required for optimum ethanol production. Once a tank is full, it will be disconnected from
the front process, and accessed by the ethanol distillation plant.
What you will do
1. You will need to understand and explain the basic process for a sugar cane molasses distillery producing 95% ethanol as its main product. Identify the key
components of safety and environmental legislation and regulations under which the facility will likely be captured. Develop preliminary process information to inform
the safety and environmental hazard assessment. This may include:
a. A brief process description;
b. Description of key unit operations;
c. Process & instrumentation diagram;
2. Description of process materials including raw materials, process additives, products and waste streams. For the production rate given above and investigated
ratios of chemical production, estimate the production rates of chemical flows (in kg/s). You do not need to calculate heating flow requirements. Undertake an initial
safety hazard assessment of the proposed facility including:
a. Identification of key hazards;
b. Assessment of raw material, chemical storage requirements and product
transportation issues.
Please reference your source(s) of process information.
3. Once you have the above information, carry out a HAZOP of the equipment and process shown in the attached process flow diagram. Make the required additions to
the diagram.
4. Describe the steps required leading up to an Environmental Impact Statement (EIS) as described in the Queensland Government website and as noted in your
lecture notes. Carry out an EIS. Include
a. Assessment of potential impacts of the facility on water, land and air systems;
b.
Assessment of process waste streams; You will need to include the consideration of options for the disposal and/or reuse of the byproduct ‘vinasse’ after the mash is
fully processed, as well as the product chemicals noted in the attached process flow diagram and
c. Mitigation options for the issues that have been identified including consideration of process alternatives.

What you will submit
You will submit a written report detailing all aspects of the hazard assessment as detailed above. Your report should be written in an appropriate engineering format
for an audience that would include Senior Managers of your company.
As an indication, the main body of the report should be approximately 3000 words not counting tables, figures, drawings, references, etc. The report should include:
• Title page
• Table of contents
• Table of figures / tables
• Executive summary
• Main body of the report
• Conclusions
• References
• Appendices if required
Formatting
• 12 point font with a standard font eg Times New Roman, Ariel, Calibri
• Use headings where necessary to break the report into meaningful sections
• Every page should be numbered; every figure and table should be numbered and captioned
• Use a standard referencing system for in-text references and bibliography
The assessment process flow diagram will be supplied in both pdf and Autocad formats. Students have the option of modifying it in Autocad for the P&ID, or, for
example, providing a well set out hand written P&ID. You will not be penalised for the form you choose.

Criteria

Criteria
Level A (Excellent)

Presentation. 5 marks
• Clear
• Good flow
• Consistent
• Easy to read
• Easy to understand
• Professional All attributes demonstrated at the highest professional standard and best practice by majority of group.
5 marks.

Technical.
5 Marks
Items –
• Legislation and
regulations
Excellent demonstration of the understanding of the legislation and regulations.
5 marks.

• Process information 5 Marks
Excellent demonstration of the understanding of the process.
5 marks.

Hazard assessment 15 Marks
Excellent demonstration of the process hazard assessment.
15 marks.

Environmental assessment
10 Marks
Excellent demonstration of the environmental assessment.
10 marks.
Information might help
Legislation and Responsibility

Queensland Government website
https://www.worksafe.qld.gov.au/licensingand-registrations/plant-design-registration

Legislation – Items of plant requiring design registration
•Pressure equipment, other than pressure piping, and
categorised as hazard level A, B, C or D according tothe criteria in section 2.1 of AS 4343:2014 (Pressure equipment – hazard levels) (page 720).
•Gas cylinders covered by section 1.1 of AS2030.1:2009 (Gas cylinders – General requirements)(page 708).
•Tower cranes including self-erecting tower cranes(page 729).
•Lifts, including escalators and moving walkways (page715).
•Building maintenance units (pages 698 – 699)
Hoists with a platform movement exceeding 2.4 m,designed to lift people (page 712).
•Work boxes designed to be suspended from cranes(page 731).
•Amusement devices covered by section 2.1 of AS3533.1 (Amusement Rides and Devices), except class1 structures specified in section 2(2) (page 694).
•Concrete placement units with delivery booms (page699).
•Prefabricated scaffolding and prefabricated formwork(page 725).

The zip file have more info