Hazard and Operability Analysis in an Acid Regeneration Reactor in Iron and Steel Industry

In this study a descriptive and cross-sectional research was carried out to identify the hazards which lead accidents and evaluate the risks in an acid regeneration reactor in Iron and Steel Industry. For that purpose Hazard and Operability Analysis (HAZOP) which is a qualitative method has been used to determine, analyse and eliminate the accidents which may occur in production process or equipment. In order to prioritize the risks, the results has been made semi-quantitative by using Risk Assesment Decision Matrix Method. At the end of the analysis 16 deviations has been identifed in 5 choosen nodes. 13 deviations caused by equipment failure and 3deviations caused by handling of the solid material. 30 results have been identified that may create the risk of accidents. 9 of them determined as equipment damage; 8 of them determined as production decrease, 6 of them determined as explosion, 6 of them determined as fire and 1 of them is determined as the release of toxic gases. In order to obtain more realistic results risk rating has been made after the system barriers; because of that there were no catastrophic, very high or high risks in this process. 36 intermediate, 3 low and 14 very low risks has been identifed. The 30 of them are effective on property, 12 of them are effective on human, 11 of them are effective on environment, there are no risks effective on prestig