A South Korean multinational manufacturing conglomerate operating across diverse sectors, including food processing, textiles, and electronics, sought a comprehensive evaluation of relief valve adequacy during an ethylene decomposition reaction at their facility. The scope of work specifically required:
ioMosaic tackled the complex challenge of evaluating relief valve adequacy via a multi-step simulation and design process.
First, the ioMosaic team completed a process simulation of the ethylene decomposition reaction to precisely determine the reaction rate of the ethylene under various conditions, based on detailed input provided by the client. Once the reaction kinetics were established, the existing relief device was rigorously tested within the simulation to evaluate whether the current system could safely handle the pressure generated by the reaction.
If the simulations determined that the existing relief device was not adequate to protect the vessel, ioMosaic sized a new relief device and its associated piping to ensure that an appropriately sized system would be in place to safely relieve the vessel during the ethylene decomposition reaction. The pressure relief system analysis and documentation were prepared using Process Safety Office® SuperChems® software.
Our analysis revealed that the client's existing relief device was inadequate to safely handle a rapid ethylene decomposition reaction. This critical finding highlighted a significant safety gap that needed immediate attention. To address this, ioMosaic recommended the installation of a 10–12-inch rupture disk, with the precise size dependent on the final system configuration. This recommendation was based on the rupture disk's fast-acting nature, which is crucial for mitigating the rapid pressure increase associated with a decomposition event.
The ioMosaic team provided the client with multiple options, allowing them to thoroughly evaluate the benefits and drawbacks of each solution. Our approach empowered the client to make a well-informed decision that prioritized the safety of their plant above all else. We also recommended further evaluation of the system after the proposed changes were implemented to ensure long-term protection and reinforcement.