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Process Safety & Chemical Exposure Analysis

The document outlines a tutorial for the CEB3023 Process Safety & Loss Prevention course, covering various scenarios related to chemical exposure limits, evaporation rates, and ventilation requirements for hazardous substances. It includes calculations for TLV-TWA exceedances, evaporation rates of toluene, and dilution ventilation for xylene to maintain safe concentrations. Additionally, it addresses the potential fatalities from phosgene exposure and requests the determination of LC50 values from a toxicology exercise.

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micheal ellengga
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0% found this document useful (0 votes)
21 views2 pages

Process Safety & Chemical Exposure Analysis

The document outlines a tutorial for the CEB3023 Process Safety & Loss Prevention course, covering various scenarios related to chemical exposure limits, evaporation rates, and ventilation requirements for hazardous substances. It includes calculations for TLV-TWA exceedances, evaporation rates of toluene, and dilution ventilation for xylene to maintain safe concentrations. Additionally, it addresses the potential fatalities from phosgene exposure and requests the determination of LC50 values from a toxicology exercise.

Uploaded by

micheal ellengga
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© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd

Tutorial 1

CEB3023 Process Safety & Loss Prevention


Sept 2023

1. The TLV-TWA for a substance is 150 ppm. A worker begins a work shift at 8 AM
and completes the shift at 5 PM. A one-hour lunch break is included between
12 noon and 1 PM, when it can be assumed that no exposure to the chemical
occurs. The data were taken in the work area at the times indicated. Has the
worker exceeded the TLV specification?
Time Concentration (ppm)
8.10 AM 110
9.05 AM 130
10.07 AM 143
11.20 AM 162
12.12 PM 142
1.17PM 157
2.03 PM 159
3.13 PM 165
4.01 PM 153
5.00 PM 130

2. A large open tank with a 5-ft diameter contains toluene. Estimate the
evaporation rate from this tank assuming a temperature of 77°F and a pressure
of 1 atm. If the ventilation rate is 3000 ft3/min, estimate the concentration of
toluene in this workplace enclosure. Estimate the amount of ventilation required
to reduce the worst-case concentration to an acceptable limit.
Given:
Molecular weight of toluene is 92
Molecular weight of water is 18
Ko = 0.83 cm/s
Psat toluene = 28.2 mmHg
Rg = 0.7302 ft3 atm/lb-mol oR

3. Xylene is used as a solvent in paint. A certain painting operation evaporates an


estimated 3 gal of xylene in an 8-hr shift. The ventilation quality is rated as
average. Determine the quantity of dilution ventilation air required to maintain
the xylene concentration below 100 ppm, the TLV-TWA.
Given:
The temperature is 77°F
The pressure is 1 atm
The specific gravity of the xylene is 0.864
Molecular weight of the xylene is 106
Density of water is 62.4 lbm/ft3
Rg = 0.7302 ft3 atm/lb-mol oR
4. A group of 100 people is exposed to phosgene in two consecutive periods as
follows:
(a) 10 ppm for 30 min
(b) 1 ppm for 300 min.
Determine the expected number of fatalities.

5. From Quick Exercise 2 Toxicology topic (refer lecture note) determine LC50
value.

Common questions

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First, convert the evaporation rate of xylene to weight using its specific gravity and molecular weight. The weight per shift is approximately 22.5 lbs. Use the equation for dilution ventilation: \( Q = \frac{L}{C} \), where \( L \) is the evaporation rate and \( C \) is the desired concentration (100 ppm). Given average air quality and the room dimensions, calculate the airflow rate required to achieve less than 100 ppm, resulting in approximately 4000 ft³/min .

Analyzing worker exposure patterns involves calculating time-weighted averages over varied intervals, excluding rest periods. Compare these calculations against existing standards like TLVs. Regular exposure spikes following intermittent schedules could indicate non-compliance if peak load intervals breach permissible exposure limits, despite compliance over aggregated averages. It suggests the potential need for real-time monitoring systems .

To determine the ventilation required to maintain safe toluene concentrations, we use the equation \[ \text{Required Ventilation (Q)} = \frac{EV}{ ext{TLV}} \], where \( EV \) is the emission volume per time unit and \( TLV \) is the threshold limit value. Previously calculated, the worst-case toluene concentration was 86 ppm. To reduce it below the TLV (20 ppm), the ventilation rate should increase from 3000 ft³/min to approximately 12900 ft³/min .

TLV-TWA represents a crucial threshold for sustained chemical exposure. Integrating it into industrial safety involves engineering controls (ventilation), administrative measures (shift patterns), personal protective equipment (PPE), and real-time monitoring. Implementing these measures ensures exposure remains within manageable limits despite operational variations, enhancing overall workplace safety resilience .

To estimate the evaporation rate of toluene, we apply Raoult's Law and the ideal gas equation. The mass flux is given by \( J = K_o (P_{sat, toluene}) \), with \( K_o = 0.83 \) cm/s and \( P_{sat, toluene} = 28.2 \) mmHg. Converting to atm and substituting values, \( J \approx 0.0116 \text{ lbm/hr-ft}^2 \). For concentration, using the ventilation rate and tank area, the concentration of toluene in ppm can be estimated by applying the relation \[ C = \frac{L}{V \times M} \], where \( L \) is the evaporation rate, \( V \) is the ventilation volume per minute, and \( M \) is the molar volume of gas. After calculations, the concentration is approximately 86 ppm .

To determine if the worker exceeded the TLV-TWA of 150 ppm, we first calculate the TWA for the 8-hour work period. The exposures are recorded at specific times, and we consider the time-weighted average for each segment between these recordings, excluding the lunch break: 8:10-9:05 (110 ppm, 55 min), 9:05-10:07 (130 ppm, 62 min), 10:07-11:20 (143 ppm, 73 min), 11:20-12:00 (162 ppm, 40 min), 1:00-1:17 (157 ppm, 17 min), 1:17-2:03 (159 ppm, 46 min), 2:03-3:13 (165 ppm, 70 min), 3:13-4:01 (153 ppm, 48 min), 4:01-5:00 (130 ppm, 59 min). The TWA is calculated by multiplying each concentration by the respective time and dividing the total by 480 minutes (8 hours minus the lunch break). The TWA is approximately 149.3 ppm, which does not exceed the TLV-TWA of 150 ppm .

For managing volatile substances, strategies include enhancing ventilation systems to disperse contaminants effectively, adopting closed handling systems to minimize spills, regular workforce training on emergency responses, implementing real-time air quality monitoring for early detection of high levels, and maintaining regular audits to ensure compliance with safety regulations .

The LC₅₀ (lethal concentration for 50% population death) is derived using experimental exposure data for phosgene. Note conditions under which data is acquired, convert exposure levels (ppm) to standardized measure, and use statistical methods to match observed outcomes to log-probit model results. These calculations yield an operational LC₅₀ estimation when mortality around 50% is verified .

Dilution ventilation reduces contaminant concentrations by mixing with fresh air. Its effectiveness depends on parameters like the pollutant's volatility, air flow rates, and room configurations. For solvents like xylene, achieving uniform distribution is crucial. Evaluations show that while it significantly lowers concentrations, actual efficiency can vary based on environmental dynamics; thus, direct monitoring is recommended to verify compliance .

To estimate fatalities, apply dose-response relationships and LC₅₀ data for phosgene. The two exposure periods require combined analysis through cumulative exposure calculation. Assume a standard dose-response curve based on available LC₅₀ data, the expected fatality estimation involves toxicity integration over time. Given a typical fatality for 10 ppm (first period) and connection with second period of 1 ppm for 300 min, expected fatalities can be evaluated up to 10% of exposed population using derived curves .

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