Question

In a plant, a particular reactor produces methyl formate from carbon monoxide and methanol using a zeolite catalyst. The reactor operates at 40 bar and 100 C.

What safety instruments should be installed to either eliminate or mitigate potential hazards?
Discuss how preventive maintenance helps us eliminate potential hazards.
What PPE should the operators wear as a precautionary measure?

Answer 1

Potential hazards

The substance is toxic to the nervous system, upper respiratory tract.Hazardous in case of skin contact (irritant), of ingestion, of inhalation. Slightly hazardous in case of skin contact (permeator).The products of degradation are more toxic.Flammable liquid with ethereal odour.

To prevent mitigate methly formate hazards

Engineering Controls:

Provide exhaust ventilation or other engineering controls to keep the airborne concentrations of vapors below their respective threshold limit value((air line respirator, and ventilator with air purifier). Ensure that the eyewash stations and safety showers are proximal to the work-station location

* Flammable materials like methyl formate should be stored in a separate safety storage cabinet or room away from heat. Keep away from sources of ignition. Keep container tightly closed. Keep in a cool, well-ventilated place. Ground all equipment containing material. A refrigerated room would be preferable for materials with a flash point lower than 37.8°C (100°F).

If spillage happens due to higher temperature and pressure, can be washed in cold water sprinkling through pipelines from the roof. Should be stored in cold condiction to avoid ignition.

Personal Protection Equipments:(PPE)

Splash goggles. Lab coat. certified vapor respirator. Gloves.

Personal Protection in Case of a Large Spill:

Splash goggles. Full suit. Vapor respirator. Boots. Gloves. A self contained breathing apparatus should be used to avoid inhalation of the product.