ETHANOL PRODUCER'S DATA BASE
Simplicity in Applied technology
SAFETY
- Safety is of utmost importance in producing, storing and handling Ethanol.
- Here are some steps towards achieving this goal.
- Please visit the library for brochures and posters on safety, that can be downloaded for free.
Safety in the work area
By applying the following five principles you will be well on the way to making
sure that you are working safely with flammable substances.
and handling areas? Ignition sources can be very varied and they include sparks from electrical equipment or welding and cutting tools, hot surfaces, open flames from heating equipment, smoking materials etc.
If you have a spill will it be contained and prevented fromspreading to other parts
Can you eliminate flammable substances from the process altogether?
You may be able to think of other ways of carrying out the job more safely
processes and general storage areas? Can they be separated by a physical barrier, wall or partition? Separating your hazards in this manner will contribute to a safer workplace.
Think about the flammable substances you have in the workplace and apply these
five principles wherever possible. Tell workers, and others who need to know, about the hazards and how they should control them.
Think: V.I.C.E.S.
DOWNLOAD BROCHURE IN PDF
Safety pressure relief valves for small boilers used in distillation
Boilers heating tanks, and all heating systems utilizing water as the heat transfer vehicle must be fitted with safety overpressure devices. These can be purchased ready built for relatively low cost considering their importance in the safe operation of a boiler that can generate a great amount of steam, and high pressures, in the case of an out of control runaway situation that may only happen once in the life of a boiler.
- Calculus: For those of you who like to calculate the risks with formulas.
- Cracking pressure: Test rig showing the pressure needed to crack the valve seat open.
- Regulations: The laws regulating the use of safety valves.
- Available types: Types of Safety valves with links to some suppliers, along with prices.
- Make your own: Safety valve can be made from:
- Simple tin can placed upside down on a pipe nipple
- Swing type Check valve
- Spring loaded check valve
...........................................
*Note on properly sizing a relief valve
"This is strictly a humorist view not to be applied verbatim"
- Fill your lungs full of air,
- Place a drinking straw in your mouth
- Pucker up your lips around the straw ( as if to sip )
- Tape your lips tightly against the straw with scotch tape
- Sniff some fine black pepper through your nostrils
- Pinch your nose, and keep it well pinched
- NOW... SNEEZE !
- The very minimum valve size to consider is 3/4"
- And should have a minimum CV of 10 and more
- CV Factor = Flow of water in GPM through the valve at 1 Psi Applied pressure.
- CV Factor = Flow of water in GPM through the valve at 1 Psi Applied pressure.
Cracking pressure of safety valves
Cracking pressure: Pressure at which the valve starts opening
I made a test rig to test the actual cracking pressures of different check valves that can be used as pressure relief valves.
- This is a test rig made with an automatic blood pressure monitor,the inflatable arm band has been replaced by the valve under test.
- The pump sends air ( to inflate the band ) and the monitor displays the line pressure which indicates the actual valve "Cracking" pressure.
==================================
SPRING LOADED CHECK VALVE AS SAFETY RELIEF VALVE
37mmHg translates into 0.72 Psi
To obtain a safe 2 Psi pressure relief, the spring that holds the valve shut, must be replaced with a stronger stainless steel spring in order to get a reading of 103 mmHg.
SPRING LOADING MECHANISM FOR A SWING CHECK VALVE
This add on mechanism makes a swing check valve adjustable to 3 psi.
You can view and download the PDF file of the drawing, parts list and instructions
by clicking on this link: View - Download PDF file.
>>>>>> Coming right up <<<<<<
NORMS COVERING THE USE OF LOW PRESSURE BOILERS AND STILLS
| COUNTRY | ORGANIZATION | APPLICABLE STANDARDS |
| International | ISO 4126 | General requirements |
| Europe | EN ISO 4126 | Overpressure devices |
| USA | API RP 520 | Pressure relief valves |
| USA | API STD 527 | PRV Seat tightness |
| USA | ASMEI | Boiler application |
| Australia | SAA AS1271 | All boiler devices |
| UK | BS 6759 | Part 1: Steam and Hot water |
| Germany | TRD 421 & 721 | Safety valves for boilers group I, II, III, IV |
| France | AFNOR NFE 29-411 to 416+421 | Safety and Relief valves |
==================================
SWING CHECK VALVE AS SAFETY RELIEF VALVE
5 mmHg translates into 0.097 Psi
==================================
MAKE YOUR OWN SAFETY RELIEF VALVE
3/4 INCH (20 mm) SWING CHECK VALVE
This is the MINIMUM SIZE valve that can safely be used for small re-boilers, it should not be used for larger boilers made with 55 Gallon drums and larger.
For 55 Gallon drums, a 1 1/4 to 2 Inch valve is by far a better choice as it will release the overpressure smoothly and without raising the pressure as the vapors are escaping.
1 1/4 INCH (32 mm) SPRING LOADED CHECK VALVE
This valve is a good second choice in and you should not hesitate if you can put your hands on a good one.
Since they are used mostly as an in well check valve for potable water pumping installations, they are normal stock at coop stores, and most hardware stores that sell household water pumping systems.
The cheapest way to build a safety relief valve is to put a tin can upside down over a pipe fitting at the highest point of the boiler (re-boiler) with a weight to hold it down.
============= = = = = = = = = = =====
Picture showing details of pipe and tin can.
Safe denaturing
Denaturing your ethanol is a simple yet very precise undertaking, that must be carried out
using authorized chemicals, in the right proportions.
Authorized Materials for Fuel Alcohol
1 The materials listed in 27 CFR 19.1005(c), in the quantities specified there.
2 The following additional materials, in the following quantities, corresponding to the following specifications:
Under 27 CFR 19.1005(b), the following materials are approved to render spirits unfit for beverage use and thus acceptable for withdrawal from alcohol fuel plants as fuel alcohol:
Material Quantity added to 100 gallons of distilled spirits Specifications Natural Gasoline 2 gallons or more 1. Natural gasoline (drip gas) is a mixture of butane, pentane, and hexane hydrocarbons extracted from natural gas. 2. Distillation range: No more than 10% of the sample may distill below 97° F.; at least 50% shall distill at or below 156° F.; and at least 90% shall distill at or below 209° F. Ethyl Tertiary Butyl Ether (ETBE) 2 gallons or more Raffinate 2 gallons or more 1. Octane (R+M/2): 66-70 2. Distillation, in Degrees F: 10%: 120-150 50%: 144-180 90%: 168-200 End Point: 216-285 3. API Gravity: 76-82 4. Reid Vapor Pressure: 5-11 Naphtha 2 gallons or more 1. API Gravity @ 60/60 Degrees F: 64-70 2. Lb/Gal: 5.845-6.025 3. Density: .7022-.7238 4. Reid Vapor Pressure: 8 P.S.I.A. Max. 5. Distillation, in Degrees F: I.B.P.: 85 Max. 10%: 130 Max. 50%: 250 Max. 90%: 340 Max. End Point: 380 6. Copper Corrosion: 1 7. Sabolt Color: 28 Min. Toluene 5 gallons or more See 27 CFR 21.131.