Process safety support was provided for the Tyre Pyrolysis Oil, TPO, project at an existing carbon black production facility. The project involved the integration of a new feedstock and associated process systems into an operating industrial plant.
The scope of work included HAZOP with LOPA elements, review of hazardous scenarios, assessment of safeguards and support in defining additional risk reduction measures where required. The study focused on credible process deviations, potential causes and consequences, operational safeguards, interlocks, alarms and safety-related procedures.
Additional support included PSSR, Pre-Start-up Safety Review, commissioning readiness activities and practical process safety support before start-up. This included review of selected procedures, operational readiness, safety requirements, equipment interfaces and actions required before safe introduction of the new medium into the installation.
Particular attention was given to hazards associated with handling and transfer of TPO, flammable and combustible materials, inerting, unloading operations, process containment, interfaces with existing plant systems and safe operation during start-up and normal production.
This project demonstrates experience in process safety support for brownfield industrial modifications, where new process media and technologies are integrated into existing high-hazard chemical production facilities.
