MATERIAL HANDLING AND STORAGE :

Storage
Every process plant requires adequate storage facilities for raw materials.
Intermediate products, final products, recycle materials, off-grade
materials, fuel etc. The requirement may be during the normal course of
operation or, for temporary procurement or emergency delivery during
plant shutdown so that the normal cycle of the plant remains unaffected.
Bulk storage and handling must be considered for any high volume
operation that uses large quantities of standard products. It has
advantages of a lower basic cost for the material purchase, a lower plant
shrinkage loss and a saving in the plant floor space as material can be
stored outdoors in tanks. However it has a big disadvantage in the form of
the huge capital investment required. Also there may be a loss in the
flexibility of operations. There is always a risk of contamination of tank by
a material of different grade or type.
Closed cylindrical or spherical tanks, to prevent the escape of volatile
matter and minimize contamination generally handle bulk storage of
liquid. Since safety is an important consideration in storage tank design,
the Indian Petroleum Institute and The National Fire Petroleum Association,
Publish rule for safe design and operation. Floating roof tanks are used to
conserve valuable products with vapor pressure below atmosphere. While
products with higher pressure must be stored in vapor tight tanks, capable
of withstanding internal pressure. If flammable liquid are stored in vented
tanks, flame arresters must be installed in all opening except connections
below liquid level.
Gases are stored at atmospheric pressure in wet or dry-seal gas-holders.
The wet-gas holder maintains a liquid seal of water or oil between the top
movable inside tank and the stationary outside tank. In the dry-seal
holder, the seal between the two tanks is made by means of means of a
flexible rubber or plastic curtain. Recent developments in bulk natural gasproduct storage show that pumping the gas into underground strata is
cheapest method available. High-pressure gas is stored in spherical or
horizontal cylindrical pressure vessels.

Handling
Material handling equipment is generally divided into two continuous and
batch types and into a class for the handling of liquids, solids or gases.
Liquids and gases are handled by means of pumps and blowers, in pipes

and ducts, and in containers such as, drums, cylinders and tank cars.
Conveyors, bucket elevators, chutes, lift trucks and pneumatic systems
may handle solids. The selection of materials handling depends upon the
cost, the work to be done and the ease of operations and the efficiency
achievable.

Factors that must be considered in selecting such equipment are as

follows.
1 Chemical and physical nature of materials being handled.
2 Type of environment and the distance through which the materials
have to be transported.
3 Quantity of material moved per unit time.
4 Nature of feed and discharge of materials-handling equipment.
5 Continuous or intermittent nature of operations.
Since the industry in question is petroleum one, extreme care should be
taken to prevent any possibility of spark generation, static electricity etc.
that may lead to chances of fire. The tanks should each be grounded to
prevent static electricity generation. While storing/handling liquids in
tanks, care should be taken that they are not sent in from great heights to
impinge directly upon the material underneath. Else, they should be sent
in by the sides of the tanks or using a support of a stick-type equipment.
Spark-resistant tools must be used. Any type of heating equipment should
not be permitted in the area where inflammable fluids may be stored. All
electrical switches, wiring should especially be properly insulated and in
good condition in the vicinity of the sensitive areas.
The storage should be kept clean, free from oily rags, unused or old
equipment. When filled drums or other containers are stored indoors, they
should be stored in non-combustible, well-ventilated structures. All
storage areas should be isolated from all sources of open flame, well
posted with signs prohibiting smoking, and adequately equipped with fire
extinguishing systems.
All tanks should have a vent pipe or sufficient area to permit escape of air
and vapors during filling operations. Flame arresters should be fixed at the
end of the vent pipe. The vents should terminate outdoors above rooflevel to prevent contamination of workroom air. Each container should
carry an identification level containing the following information-name and
address of manufacturer, quality in kilograms or liters.

Lube oil base stock

Lubricants can deteriorate in storage, usually as a result of one of the following causes:
1. Contamination, most frequently dirt and water
2. Exposure to excessively high and low temperatures
Some contaminated or deteriorated lubricants can be reconditioned for use, while others must
be degraded to inferior applications, destroyed or otherwise disposed of. In addition, portions
of some contaminated products may be salvaged for use. The decision of which course of
action to follow depends on such factors as the amount of product involved and its value
compared to the cost of reconditioning or salvaging, the type and amount of contaminant
present, the degree of deterioration that has occurred, and the effect of the contamination or
deterioration on the functional characteristics of the product in the target application(s).

Contamination
The easiest way to control and particularly exclude contamination is to avoid using
practices that risk exposing the lubrication to the environment and surfaces/objects that
bear various forms and types of contaminants. Among other things, this guideline is
designed to offer practical advice on how to exclude and monitor contaminants of various
types from bulk lubricants in storage and handling. Contamination of lubricants is one of
the most significant factors affecting the storage stability and service life of bulk oils.
Common types of contamination are discussed below:
Condition of Storage and Handling equipment:
Contamination of newly commissioned storage and handling equipment include
preservatives, paint, moisture, rust particles and fabrication debris such as dust, dirt, or
welding spatter, machining swarf, drill turnings, blasting sand and casting sand. To avoid
contamination of bulk lubricants, appropriate care must be taken during manufacture,
assembly, installation, servicing, repair, and conditioning of tanks and equipment. Before
use, storage tanks should be thoroughly cleaned, scale-free and treated internally with a
protective coating or sealant that is compatible with the lubricants these surfaces will
contact. Tanks and vessels should be carefully dried and cleaned before they are charged
with a lubricant to be stored.
Solid Contamination
Solid contamination includes the additive residue (byproduct of degraded additives), paint
chips, rust particles, and weld splatter that may pre-exist within the tank when first
commissioned. Solid contaminants can also enter the tank through the breathers,
inspection hatches, clean-out portals and through transfer hoses when filling the tank.
Liquid Contamination
Moisture, solvents, fuels, and other incompatible lubricants are harmful contaminants as
well. Entrained water promotes base oil degradation and additive depletion. Dissolved,
emulsified and free water all pose potential risks. In additions to distress imposed by
water on additives and base oil oxidation, free water in bulk storage vessels provides a
habitat for microbial contamination which is corrosive and harmful to lubricant
performance properties. Lubricants in storage are most prone to become contaminated

with water from headspace condensation. There are many other sources of water as well.
Emulsified water has a tendency to also impair air release properties of oil. When air fails
to detrain (release air to the headspace) a common consequence is oil oxidation.
Thermal Degradation of Lubricants
Most good quality synthetic and conventional mineral oils are not affected by storage
temperatures below 120F (49C). However, storing lubricants near furnaces, steam lines
or direct sunlight in high temperature climates for a prolonged time period may cause
additives and base oils to oxidize prematurely. A significant darkening of the oil color is
an indicator of this condition. In greases, the oil may begin to separate from the thickener;
this is known as bleeding. The separated oil will typically appear on the surface of the
grease, depending on the type of thickener used. In certain cases, when there has been
oil/thickener separation, working the grease (mechanical agitation) can return the oil to
the bulk lubricant. However, this is not recommended if the top grease surface has an
accumulation of dirt. Lubricants that are potentially contaminated with volatile products,
including diesel fuel, kerosene, or any other solvent, must never be stored in high
temperatures. The presence of solvents can be identified by a test called the flash point
test. In addition to evaporation and fire hazards, they can distort or even burst the storage
vessel if tightly sealed.
Material of construction of storage tanks:
Storage tanks can be made from either stainless steel, mild steel plate, or anodized
aluminum. Stainless steel and anodized aluminum have a relatively high material cost. In
return, their maintenance costs are low. In certain cases, a thinner-gauge stainless steel
may also be suitable to better contain the costs of construction. Mild steel plates are more
commonly used for bulk storage tanks. The material cost is relatively low, but they
require more expensive cleaning and corrosion-resistant treatments. Some mild steel tank
designs and fabrication processes require shot or sand blasting plus performing one of the
following depending on the type of product to be stored: lanolin-based rust preventative,
oil-resistant paint, coating with plastic or epoxy resins or, aluminum spraying. Galvanized
steels should not be used for tanks or piping due to risks associated with additive
reactions in the formulated oil. Tank seams should be riveted or welded.
Methyl Ethyl Ketone:
Classified as Highly Flammable and Irritating to the eyes and respiratory system
Fire fighting measures:
Extinguishing Media: Foam, Dry Powder, Co2. Water spray may not be effective for fire
fighting but use to disperse vapours and protect fire fighters. Do not use water jets.
Protective Equipment: Fire fighters should enter area wearing breathing apparatus and
protective clothing.
Special Consideration: Fire exposed containers should be sprayed with water to keep cool
and avoid bursting.
Products of Combustion: Carbon Dioxide, Water and possibly Carbon Monoxide.
Accidental release measures
Do not allow product to soak into drains, water courses, sewers or pits where the vapour
may produce an explosive atmosphere. Soak liquid in absorbent material and collect

solids in a container. Wash down floor area as spillages can be slippery. Where spillage
has occurred, personnel should wear suitable protective clothing and respirators where
there is a risk of exposure to high vapour levels.
Storage Precautions:
Store in accordance with the Highly Flammable Liquids and Liquefied Petroleum Gases
Regulations.
Handling:
Avoid inhaling vapour. Avoid contact with skin and eyes. Handle in a well ventilated area.
All storage and transfer systems should be earthed to prevent build up of static discharge.
Observe good standards of industrial hygiene.
Propane
Physical properties:
Molecular weight : 44.096 g/mol
Liquid phase
Liquid density (1.013 bar at boiling point) : 580.88 kg/m3
Liquid/gas equivalent (1.013 bar and 15 C (59 F)) : 305.9 vol/vol
Boiling point (1.013 bar) : -42.11 C
Latent heat of vaporization (1.013 bar at boiling point) : 425.59 kJ/kg
Vapor pressure (at 21 C or 70 F) : 8.587 bar
Critical point
Critical temperature : 96.74 C
Critical pressure : 42.51 bar
Critical density : 220.48 kg/m3
Gaseous phase
Gas density (1.013 bar at boiling point) : 2.417 kg/m3
Gas density (1.013 bar and 15 C (59 F)) : 1.8988 kg/m3
Compressibility Factor (Z) (1.013 bar and 15 C (59 F)) : 0.98194
Specific gravity : 1.55
Specific volume (1.013 bar and 25 C (77 F)) : 0.546 m3/kg
Heat capacity at constant pressure (Cp) (1.013 bar and 25 C (77 F)) : 7.430001E-02 kJ/
(mol.K)
Heat capacity at constant volume (Cv) (1.013 bar and 25 C (77 F)) : 0.0654 kJ/(mol.K)
Ratio of specific heats (Gamma:Cp/Cv) (1.013 bar and 25 C (77 F)) : 1.1364
Viscosity (1.013 bar and 0 C (32 F)) : 7.4692E-05 Poise
Thermal conductivity (1.013 bar and 0 C (32 F)) : 15.65 mW/(m.K)
Since it is highly flammable propane must be stored in sealed containers and should be
regularly checked for any leaks in the pipes or storage tanks.
Furfural as well is easily oxidised and is flammable so its leakage has to be prevented.
Reduce or avoid exposure or contact with the chemical. It is advised to use earthed

equipment. Do not discharge the waste into the drain. It should be stored in a dark place
stainless steel, steel aluminium or iron vessels can be used for storage. Should be kept
away from heat sources and it stored for long periods, it should be stored in dark. Storage
temperature : 20 degree Celsius.
Storage Tanks Mild steel, butt-welded tanks are suitable for normal storage conditions.
Welding should be done with appropriate rods such as those containing .5% molybdenum.
Annealing to prevent stress corrosion cracking is not required unless temperatures greater
than 120F (49C) are expected. If iron pickup from mild steel tanks is a problem, the tanks
may be lined with a suitable caustic soda-resistant coating. Vertical tanks are preferred over
horizontal tanks since they take up less space and are easily supported on concrete slabs.
Tank bottoms should be set in an asphalt grout for protection from exterior corrosion. All
connections at the top of a tank should be grouped in one small area near the edge of the tank
to permit servicing from a single location.Storage tanks should be heated and insulated if
sustained ambient temperatures below 65F (18C) are expected. The thickness of the
insulation will depend upon the energy costs of heating. The insulation must be wellprotected
with jacketing to keep it dry.Heating can be accomplished with steam coils or electrical
heating tape. For internal tank heating, a nickel bayonet-type heat exchanger is
recommended.
The heater should be attached to a nickel flange, which can be fitted to a tank nozzle opening
close to the bottom of the tank. The horizontal heater should be supported about eight inches
(20cm) above the bottom of the tank and extend across the storage tank to about one foot
(30cm) from the opposite side. As the caustic soda solution around the heater is warmed, a
thermal agitation pattern will form in the tank, resulting in uniform heating of all caustic soda
solution. A maximum of 15 psig (104 kPa) steam is recommended for heating the caustic
soda solution.A temperature controller should be installed to maintain a caustic soda solution
temperature of 85100F (2938C). The controller should include a high-temperature
alarm and a thermocouple at the same liquid level as the steam coil. This guard against the
thermocouple reading a false air temperature, causing the coils to overheat the remaining
caustic solution when the tank is nearly empty. Another thermocouple located at eye level is
convenient.Valves should never be installed in the vent line. It must be open to the
atmosphere at all times.