Safety Concept for DGE Pyrolysis/Thermolysis Plants

Safety Concepts

• Are there still a risc reflection? (HAZOP)
• Are there still a safety and healthy concept?(SiGe)
• Are there still a explosion concept? (ATEX)
• Are there still a fire protection concept?

Protection of Healthy

Has the operator during regular operation contact with the products?

• Is the feeding educt toxic (ex.g. dioxine), bacterial (ex.g. undigested sludges) or virulent (ex.g. hospital waste)?
• Thermolysis-/pyrolysis oils aren't cooking oil, mostly they contains harmful substances (even super benzine). It is secured that there are safety measure / safety equipment during decanting?
• Thermolysis-/pyrolysis coke will be after correct processing nontoxic, but the fine dust will be very harmf! Did they process the carbon dust in closed equipment to safe life and environment?
• Thermolysis-/pyrolysis gases contains hydrogen & methane (explosive!) and higher amount of carbon monoxide (toxic!). Are there sensors for wanrning the operators?

Will the operator / maintenancer come in dangerous situations during emergency case / maintenance?

• Are there sensors advising against toxic gases?
• Is the maintenance allowed without protective equipment?
• Is it possible that the operator can do maintenance in protective equipment? (ex.g. fitting)

Protection of Environmental

Is the plant during regular operation really emission free?

• Is there a certified emission monitoring?
• Will the flows automatic measured by sensors and long time monitored?
• Are there sensors in critical plant parts (ex.g. sealings), which warn in emergency case? And therefor protect the personals healthy?

Is the plant prepare for emergency cases?

• Are there qualified sensors, which can steadily detect critical situations?
• A simple control circuit is impossible to control complex processcoherences! Is the control system usefull for emergency control?
• Are tanks and vessels prepared for possible leakages? (ex.g. controlled double wall or collecting tray?)
• Combustions parameters depending on gas compositionon and corrctzly working fans. Are there effectfully and quickly working emergency routines for the case of overheating? (within seconds and minutes?)
• Is there the possibility of remote controll for manufacturer's experts?

Protection during Operation

Is the plant really dessigned for continuous operations?

• Are the selected materials really useful for 100,000 h permanant operation?
• Is there a safety margin in calculation/thickness, to guarantee fully function also in case of corrosion?

Are there redundances implemented?

• Is there espacially the condensation unit redundant and can be cleaned during operation?
• Are important sensors executed redundant and due to SIL-specification in different measurement methods?
• Are redundant sensors executed correctly even in case of temporarily misfunction?

Protection of Invest

Is the plant desgined maintenance friendly for short shutdowns?

• low energy costs durinh operation
• short maintenance times -> operating time >7500h/a ? >8000h/a ? >8200 h/a ?
• long life cycle; guaranteed future by (better than) state of the art technology

• Is the the possibility of quick and safety startup and shut down?
• Is there the possibility of short maintenance, even during operation?
• Could the wear parts quickly changed?
• Is maintenance possibly with simple tools?