표제지
목차
국문초록 8
1. 서론 9
2. 이론 10
가. 폐가스 처리공정 개요 10
1) 폐가스의 정의 10
2) 폐가스 처리공정 10
나. 폐가스 처리공정의 단위공정 또는 설비 24
1) 플래어 시스템 및 구성설비 24
2) 소각공정 및 구성설비 32
3) 스크러버에 의한 흡수(중화)공정 및 구성설비 40
4) (활성탄)흡착탑에 의한 흡착공정 및 구성설비 46
5) 대기 벤트공정 및 설비 52
3. 연구방법 56
가. 폐가스 처리공정 관련 국내 안전기술기준 내용 분석 방법 56
나. 폐가스 처리공정 사고사례 분석 방법 56
1) 중대산업사고 및 공정안전관리(PSM) 대상 사업장의 정의 57
2) 공정안전관리(PSM) 대상 사업장 현황 57
3) 폐가스 처리공정에서 발생한 중대산업사고 60
4) 공정안전관리 비대상 사업장의 폐가스 처리시설에서 발생한 사고 60
5) 사고사례를 통한 사고원인 및 예방대책 제시 60
다. 폐가스 처리공정 공정별 위험성 평가 방법 62
1) 공정별 HAZOP 위험성 평가 62
라. 공정안전보고서(PSM) 보완내용 분석 방법 85
4. 분석 및 고찰 86
가. 폐가스 처리공정 관련 국내 안전기술기준 내용 분석 86
1) 플래어 시스템 관련 KOSHA GUIDE 내용 분석 86
2) 소각 공정 관련 KOSHA GUIDE 내용 분석 92
3) 흡수 공정 관련 KOSHA GUIDE 내용 분석 97
4) 흡착 공정 관련 KOSHA GUIDE 내용 분석 100
5) 대기 벤트 공정 관련 KOSHA GUIDE 내용 분석 103
나. 폐가스 처리공정의 사고사례 분석 및 고찰 105
1) 폐가스 처리공정의 사고사례 분석 105
2) 인화성 증기 사고 1건 및 독성물질 누출사고 1건에 대한 사례연구 실시 109
3) 사고사례 분석 및 연구를 통한 안전성 향상방안 제시 144
다. 폐가스 처리공정 공정별 위험성평가 결과 147
1) 각 공정의 구간별 '이탈' 도출 147
2) 폐가스 처리공정의 HAZOP 위험성평가 수행결과 153
3) HAZOP 위험성평가 결과에 따른 안전성 향상 방안 165
라. 공정안전보고서(PSM) 보완내용 분석 및 고찰 168
1) 공정별 공정안전보고서 보완내용 분석 168
2) 공정안전보고서 보완내용 분석에 따른 안전성 향상 방안 176
마. 폐가스 처리공정의 안전성 향상 방안 제시 187
1) 플래어 시스템 안전성 향상 방안 187
2) 소각 공정 안전성 향상 방안 188
3) 흡수 공정 안전성 향상 방안 189
4) 흡착 공정 안전성 향상 방안 189
5) 대기 벤트 공정 안전성 향상 방안 190
5. 결론 191
6. 참고문헌 193
Abstract 197
Appendix 198
Table 3-1. Hazardous material threshold quantity 58
Table 3-2. PSM sites in Korea 59
Table 3-3. Number of major industry accidents(MIAs)('96~'11) 61
Table 3-4. Guide words at the continuous process 63
Table 3-5. Study nodes for each process 79
Table 3-6. Frequency criteria 81
Table 3-7. Severity criteria 82
Table 3-8. Risk(severity and frequency matrix) criteria 83
Table 3-9. Criteria of risk control 84
Table 4-1. Purge gas velocity 91
Table 4-2. Analysis of MIAs occurred at the off gas treatment process 106
Table 4-3. Analysis of the fire and explosion accident occurred at the incineration and adsorption process 108
Table 4-4. Properties of materials related to the accident 110
Table 4-5. Blower specification 111
Table 4-6. Specification of tanks 112
Table 4-7. Operation step of the blowing system when starting up 122
Table 4-8. Properties of material related to the accident 128
Table 4-9. Specification of the HCl column 129
Table 4-10. PSV specification 130
Table 4-11. Weather condition 135
Table 4-12. Result of the ALOHA program 136
Table 4-13. Result of the K-CARM program 139
Table 4-14. Result of the PHAST program 140
Table 4-15. Guide words for study nodes of the flare system 148
Table 4-16. Guide words for study nodes of the incineration process 149
Table 4-17. Guide words for study nodes of the absorption process 150
Table 4-18. Guide words for study nodes of the adsorption process 151
Table 4-19. Guide words for a study node of the venting process 152
Table 4-20. HAZOP execution report for the node 1 of the flare system 154
Table 4-21. HAZOP execution report for the node 2 of the flare system 155
Table 4-22. HAZOP execution report for the node 3 of the flare system 156
Table 4-23. HAZOP execution report for the node 4 of the flare system 157
Table 4-24. HAZOP execution report for the node 1 of the incineration process 158
Table 4-25. HAZOP execution report for the node 2 of the incineration process 159
Table 4-26. HAZOP execution report for the node 1 of the absorption process 160
Table 4-27. HAZOP execution report for the node 2 of the absorption process 161
Table 4-28. HAZOP execution report for the non-regenerable adsorption process 162
Table 4-29. HAZOP execution report for the regenerable adsorption process 163
Table 4-30. HAZOP execution report for the venting process 164
Table 4-31. Classification of PSM recommendations for the flare system 169
Table 4-32. Classification of PSM recommendations for the incineration process 171
Table 4-33. Classification of PSM recommendations for the absorption process 172
Table 4-34. Classification of PSM recommendations for the adsorption process 174
Table 4-35. Classification of PSM recommendations for the venting process 175
Table 4-36. Considerable PSM recommendations for the flare system(1) 177
Table 4-37. Considerable PSM recommendations for the flare system(2) 178
Table 4-38. Considerable PSM recommendations for the flare system(3) 179
Table 4-39. Considerable PSM recommendations for the incineration process 181
Table 4-40. Considerable PSM recommendations for the absorption process 183
Table 4-41. Considerable PSM recommendations for the adsorption process 185
Table 4-42. Considerable PSM recommendations for the venting process 186
Figure 2-1. Schematic diagram of the flare system 12
Figure 2-2. Schematic diagram of the thermal and catalytic oxidizer system 14
Figure 2-3. Scrubber using in the absorption treatment process 16
Figure 2-4. Schematic diagram of the regenerable adsorption process 17
Figure 2-5. Schematic diagram of the vent stack and the venting tube 19
Figure 2-6. Schematic diagram of the cooling condensation treatment process 20
Figure 2-7. Schematic diagram of the biological treatment process 22
Figure 2-8. Schematic diagram of the off gas treatment process using the membrane 23
Figure 2-9. Schematic diagram of the knockout drum 26
Figure 2-10. Schematic diagram of the seal drum 27
Figure 2-11. Schematic diagram of the gas seal 30
Figure 2-12. Flare stack types 31
Figure 2-13. Schematic diagram of the regenerative thermal oxidizer(RTO) 34
Figure 2-14. Schematic diagram of the 2-BED RTO system 35
Figure 2-15. Schematic diagram of the 3-BED RTO system 37
Figure 2-16. Schematic diagram of the rotary wing RTO 38
Figure 2-17. Schematic diagram of the packing tower 42
Figure 2-18. Schematic diagram of the tray tower(left) and the spray tower (right) 43
Figure 2-19. Schematic diagram of the venturi scrubber 45
Figure 2-20. Activated carbon and the break point curve 47
Figure 2-21. Schematic diagram of the fixed adsorption tower 49
Figure 2-22. Schematic diagram of VRU system 51
Figure 2-23. Schematic diagram of the hydrogen vent stack(left) and the quench drum(right) 54
Figure 2-24. Schematic diagram of the safety valve and the venting tube 55
Figure 3-1. Study node 1 at the flare system 65
Figure 3-2. Study node 2 at the flare system 66
Figure 3-3. Study node 3 at the flare system 68
Figure 3-4. Study node 4 at the flare system 69
Figure 3-5. Study node 1(bottom) and 2(top) at the incineration process 71
Figure 3-6. Study node 1(left) and 2(right) at the absorption process 73
Figure 3-7. Study node at the not-regenerable adsorption process 75
Figure 3-8. Study node at the regenerable adsorption process 76
Figure 3-9. Study node at the venting process 78
Figure 4-1. Schematic diagram of the incineration process. 114
Figure 4-2. Blowing system at the incineration process(before and after) 121
Figure 4-3. Use of detonation flame arresters in piping system 124
Figure 4-4. Rupture disk positioned right before the deflagration flame arrester in piping system 125
Figure 4-5. Use of the deflagration flame arrester of the hood type on the storage tank 126
Figure 4-6. Schematic diagram of the HCl release accident process. 131
Figure 4-7. HCl Concentration graph 141
Figure 4-8. Safety valve outlet at the venting process(before and after) 143