Aloha Final Report SKVP

Project Report (PRT-S401)
Study of dispersion of toluene through a tank hole via Aloha software
Submitted in partial fulfilment of the requirement for the award of degree of
Bachelor of Technology in Chemical Engineering
By
Kunal Singh Maurya CSJMA20001390223

Priyam Pandey CSJMA20001390238
Sudhanshu Srivastav CSJMA20001390255
Vaibhav Jaiswal CSJMA20001390259
Under the Guidance of
Dr. Umesh Chandra Sharma
December 2023
DEPARTMENT OF CHEMICAL ENGINEERING

UNIVERSITY INSTITUTE OF ENGINEERING AND TECHNOLOGY
CHHATRAPATI SHAHU JI MAHARAJ UNIVERSITY KANPUR
CONTENTS
Page no.
Acknowledgement (i)
Certificate (ii)
Problem Statement 1
CHAPTER–1 Objective and Theory 5-11
CHAPTER-2 Basic Procedure 12-15
CHAPTER-3 General cases for Chemical leakage 16-27
CHAPTER-4 Observation on different possible diameter 28-43
CHAPTER-5 Real Life Example: for minimum impact 44-46
Conclusion 47-51
Summary 52
References 53
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Acknowledgement
We express our heartfelt gratitude to everyone who contributed to the successful completion
of our final year project on the "Study of Dispersion of Toluene through a Tank Hole via
Aloha Software." Under the invaluable guidance of Dr. Umesh Chandra Sharma, our project
supervisor, we received continuous encouragement and support, shaping the direction of our
research.
Our thanks extend to the Department of Chemical Engineering at the University Institute of
Engineering & Technology, Chhatrapati Shahu Ji Maharaj University, Kanpur, for providing
essential resources and facilities. The ALOHA software development team's efforts in
creating a powerful modeling tool were crucial, enabling us to analyze chemical dispersion
scenarios accurately.
Special recognition goes to our fellow group members, Kunal Singh Maurya, Priyam Pandey,
Sudhanshu Srivastav, and Vaibhav Jaiswal, for their dedicated efforts and collaboration,
contributing significantly to the project's success. Lastly, we acknowledge the unwavering
support of our families and friends, serving as a constant source of motivation throughout the
project.
The collective efforts, guidance, and support from these individuals and organizations made
this project possible. We are grateful for the knowledge gained and hope that our research
will contribute to the field of chemical engineering and emergency response strategies. Thank
you all for being an integral part of our academic journey.
Sincerely,
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CERTIFICATE
This is to certify that the report titled "Study of Dispersion of Toluene through a Tank Hole
via Aloha Software" has been successfully completed by:
for the fulfillment of the requirements of the final year project in the DEPARTMENT OF
CHEMICAL ENGINEERING at UNIVERSITY INSTITUTE OF ENGINEERING AND
TECHNOLOGY, CHHATRAPATI SHAHU JI MAHARAJ UNIVERSITY KANPUR
Project Supervisor: Dr. Umesh Chandra Sharma
Date of Submission:13/12/2023
This report reflects their original work and has been examined for its content and
presentation. It is hereby approved for submission.
Signature
Problem Statement:
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To understand the behaviour of toluene dispersion in the event of a tank hole at different
diameter breach and its implications for safety and discuss the practical application of
ALOHA simulation results for enhancing safety protocols, and risk assessment in chemical
engineering environments.
Chapter-1 (Objective and Theory)
Objective:
The objective of this analysis is to assess and compare the potential threat zones and
associated hazards in five distinct scenarios involving the release of toluene in Kanpur, India.
By evaluating the varying outcomes of heavy gas releases, thermal radiation, non-exceedance
of hazardous levels, potential flammable areas, and the absence of vapor cloud explosions,
this analysis aims to:
 Identify the factors and conditions contributing to the different threat zone scenarios.
 Provide insights into the critical parameters affecting the extent and severity of
chemical-related hazards.
 Offer valuable information to support emergency responders and planners in
developing effective safety strategies and response plans for chemical incidents in the
region.
 Facilitate a better understanding of the potential risks associated with toluene releases
and aid in making informed decisions regarding risk mitigation and emergency
preparedness.
Introduction:
This report presents an analysis of five distinct scenarios involving the release of toluene in
Kanpur, India. Each case explores the potential threat zones and associated hazards, taking
into account various factors, including chemical properties, atmospheric conditions, and
source characteristics. The outcomes range from heavy gas releases to thermal radiation, and
from no exceedance of hazardous levels to potential flammable areas. This analysis serves to
provide critical insights for emergency responders and planners in addressing chemical-
related safety challenges.
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Theory:
About ALOHA®
ALOHA (Areal Locations of Hazardous Atmospheres) is a modeling program that estimates
threat zones associated with hazardous chemical releases, including toxic gas clouds, fires,
and explosions. A threat zone is an area where a hazard (such as toxicity) has exceeded a
user-specified Level of Concern (LOC). ALOHA is part of the CAMEO® software suite of
products for emergency responders and planners.
Key Program Features
 Generates a variety of scenario-specific output, including threat zones, threat at
specific locations, and source strength graphs.
 Calculates how quickly chemicals are escaping from tanks, puddles (on both land and
water), and gas pipelines—and predicts how those release rates change over time.
 Models many release scenarios: toxic gas clouds, BLEVEs (Boiling Liquid
Expanding Vapor Explosions), jet fires, vapor cloud explosions, pool fires, and
flammable areas. See available scenarios by release source type...
 Evaluates different types of hazards (depending on the release scenario): toxicity,
flammability, thermal radiation, and overpressure.
 Displays threat zones on MARPLOT maps (and also on Esri's ArcMap with
the ALOHA ArcMap Import Tool and Google Maps and Google Earth using
the export as KML feature).
 Works seamlessly with companion programs CAMEO Chemicals and MARPLOT®;
it can also be used as a standalone program.
ALOHA's menus are set up so that you typically move left-to-right through ALOHA's Site
Data, Setup, Display, and Sharing menus as you enter information about a scenario. If you
haven't completed all of the necessary information in an earlier step, you will find that menu
items remain grayed out in the menus further to the right.
To use ALOHA, you'll typically perform several basic steps:
1. Enter site information by indicating the city where a chemical release is occurring and
the date and time.
2. Choose the chemical of concern from ALOHA's library of chemical information.
3. Describe the weather conditions and ground roughness at the release site.
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4. Set the source by describing how the chemical is escaping from containment (e.g.,
liquid leaking from a tank).
5. Display a threat zone estimate, showing one or more areas where a hazard—toxicity,
flammability, thermal radiation, or damaging overpressure—may exceed key Levels
of Concern (LOCs) and pose a threat to people and property.
 If three LOCs are chosen, ALOHA will display the threat zones in red, orange,
and yellow. The red threat zone represents the worst hazard; the orange and
yellow threat zones represent areas of decreasing hazard.
 If you're modeling a chemical that is both toxic and flammable, you may want
to model several different scenarios and compare the threat zone estimates.
For example, for a vapor cloud release, you may be able to compare the toxic
area of the cloud against the flammable area (if the cloud encountered an
ignition source) and the blast area (if a vapor cloud explosion occurred). If the
chemical is nonflammable, ALOHA will automatically choose the toxic
scenario, since the fires and explosions scenarios can't be used with
nonflammable chemicals.
If desired, export the threat zone so that it can be displayed on a map. The CAMEO
software suite includes a mapping program, MARPLOT, that displays ALOHA threat
zones easily (a sample is shown below). Additionally, ALOHA's threat zones can also
be exported to Esri's ArcMap (with the ALOHA ArcMap Import Tool ) and to
Google Maps or Google Earth (via ALOHA or MARPLOT).
Fig. 1
As you become more familiar with ALOHA, you may move beyond the basic steps and start
considering some of ALOHA's other output. For example, you can use the Threat at
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Point feature to obtain specific information about the hazards at points of interest (such as
schools and hospitals) in and around the threat zones. ALOHA will display the threat at a
point either as a graph or as text. For instance, if you choose to see the threat at a point for a
toxic gas dispersion scenario, ALOHA will display a graph showing predicted indoor and
outdoor chemical concentrations at the location for the first hour after the release.
Note: You can save ALOHA results as archive files, and you can copy and paste graphs,
pictures, and text information from ALOHA into documents or reports in word processing or
graphics programs.
Threat Zone
A threat zone is the area within which ALOHA predicts the hazard level to exceed your Level
of Concern (LOC) at some time after a release begins. ALOHA can model multiple
hazards (toxicity, flammability, thermal radiation, or overpressure), and the type of LOC that
you choose will vary based on the hazard.
For each scenario, you may specify up to three LOCs in ALOHA. If three LOCs are chosen,
ALOHA will display the threat zones in red, orange, and yellow, overlaid on a single picture.
By default, the red zone represents the worst hazard. (The pattern of dots also varies for each
threat zone so that you can differentiate between the zones if you are color blind or the
picture has been printed in black and white.)
Note that threat zones displayed in ALOHA are always drawn with the downwind
direction to the right—that is, moving across the threat zone window from left to right is the
same direction that the wind is moving. It is not an indication of the cardinal wind directions;
so, for example, going to the right does not necessarily mean that the wind is coming from
the "west". To see the threat zone drawn based on cardinal wind direction (for example,
shifted based on a wind coming from the south), display it on a map.
Here is an example of a threat zone for a toxic vapor cloud:
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Fig. 2
For dispersion scenarios (toxic threat zones [as shown above], flammable areas, and vapor
cloud explosions), the dashed lines along both sides of the threat zone represent uncertainty
in the wind direction. The wind rarely blows constantly from any one direction. As it shifts
direction, it blows the released chemical in a new direction. The wind direction confidence
lines around the threat zone enclose the region within which—about 95 percent of the time—
the chemical cloud is expected to remain. The lower the wind speed, the more the wind
changes direction, so as wind speed decreases, the wind direction confidence lines become
farther apart. (They form a circle when wind speed is very low.)
Below is an example of a threat zone for a BLEVE, where ALOHA is modeling the thermal
radiation hazard. This threat zone is also oriented so that the downwind direction is to the
right; however, note that a thermal radiation hazard is predicted in all directions and is not
dependent on the wind for distribution. There are no wind direction confidence lines for non-
dispersion scenarios—pool fires, jet fires, and BLEVEs.
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Fig.3
Displaying a Threat Zone
Once you have entered all necessary information about a release, choose Threat Zone from
the Display menu. If the Threat Zone menu item appears grayed out (so that you cannot select
it), ALOHA still requires more information from you to make its computations. Check
the Text Summary window to see what's missing.
In most cases, asking ALOHA to display the threat zone will first bring up a dialog box
where you can set your LOCs. In such cases, ALOHA had already determined the hazard to
model based on your scenario details, and it will display a threat zone after you enter the
LOCs. However, if ALOHA can model more than one hazard for your scenario, it will first
ask you which hazard to analyze and—if you select the blast area for a vapor cloud explosion
—it will also ask for additional vapor cloud explosion inputs before you can set your LOCs.
Chemical Theory:
Chemical Name: Toluene
CAS Number: 108-88-3
Molecular Weight: 92.14 g/mol
Toxicity Levels:
AEGL-1: Toluene exhibits mild and transient effects at concentrations around 100 ppm,
indicating a low level of short-term exposure risk.
AEGL-2: Concentrations of around 400 ppm can result in irreversible or long-lasting health
effects, underscoring the importance of minimizing exposure to prevent adverse health
outcomes.
AEGL-3: Life-threatening effects become a concern at or above 2000 ppm, emphasizing the
critical need for stringent safety measures and exposure controls.
IDLH: The Immediately Dangerous to Life or Health (IDLH) concentration is set at 500
ppm, indicating the level at which there is a potential for immediate adverse effects.
Flammability Levels:
LEL: Toluene's lower explosive limit (LEL) is approximately 1.2% in air, signifying its
potential to form flammable mixtures at relatively low concentrations.
UEL: The upper explosive limit (UEL) is about 7.1% in air, marking the upper boundary for
safe handling to prevent explosive atmospheres.
Physical Properties:
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Ambient Boiling Point: Toluene has a boiling point of 110.6°C (231.1°F) under standard
atmospheric conditions.
Vapor Pressure: At 20°C (68°F), toluene exhibits a vapor pressure of approximately 28.3
mm Hg, indicating its propensity to evaporate into the air.
Saturation Concentration at 20°C: The saturation concentration of toluene in air at 20°C is
approximately 780 mg/L, providing insight into its volatility.
Related Topics
 Hazard to Analyze
 Entering Vapor Cloud Explosion Parameters
 Setting Levels of Concern
 Interpreting a Threat Zone
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Chapter-2 - (Basic Procedure)
Requirement:
 A computer or Laptop with Net connected.
 Aloha Software Installed in it.
Methodology-
Layout & Tool:
Fig.4
Site Data:
Fig.5 (a)
Fig.5(b)
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Fig.6
Atmospheric Conditions:
In this hypothetical scenario, the incident occurred under specific meteorological conditions.
The date and time of the event were taken as theoretical variables. The prevailing wind
exhibited a speed of 5 miles per hour, originating from the south, at a height of 10 meters.
The environment, characterized by either urban or forest ground roughness and 5 tenths cloud
cover, played a crucial role in shaping the atmospheric dynamics. The air temperature stood
at 30°C, indicating a relatively warm climate. Additionally, the stability class and inversion
height, if applicable, contributed to the overall atmospheric conditions. With a relative
humidity of 40%, these combined factors create a detailed snapshot of the environmental
parameters surrounding the hypothetical incident. The interplay of these meteorological
elements can significantly influence various aspects of the incident, from air quality to
potential impacts on surrounding areas.
Fig.7(a) Fig.7(b)
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Source Strength:
In this incident, the source is identified as a Toluene leak originating from a cylindrical tank
situated at CSJMU, Kanpur. The potential causes of the leak include corrosion, overpressure,
improper installation, lack of maintenance, and manufacturing defects. The tank, a vertical
cylinder, possesses specific dimensions with a diameter of 7 meters and a length of 29
meters, resulting in a total volume of 141 cubic meters. At the time of the incident, the tank
was approximately 81% full with Toluene.
The chemical within the tank was at a temperature of 30°C. The cylindrical tank featured a
circular opening with a diameter of 0.2 inches. In the event of a leak, this opening served as
the point of discharge for the Toluene.
The location of the incident at CSJMU, Kanpur, adds a geographical context to the situation.
Understanding the environmental conditions previously described, including wind speed,
ground roughness, and cloud cover, becomes crucial in assessing the potential dispersion and
impact of the released Toluene.
As a result of the Toluene release, specific fire-related parameters need consideration for the
report. This includes information on the maximum flame length, burn duration, burn rate, and
the total amount of chemical burned. These details are essential for evaluating the severity of
the incident, its potential consequences, and informing appropriate response and mitigation
measures. The comprehensive documentation of these factors contributes to a thorough
understanding of the incident for further analysis and preventive measures.
Fig.8
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Fig.8(a)
Fig.8(b)
Fig.8(c)
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Chapter-3
(General cases for Chemical leakage)
Case 1: Leaking tank, chemical is not burning and forms an
evaporating puddle.
SITE DATA:
Location: KANPUR, INDIA
Building Air Exchanges Per Hour: 0.38 (unsheltered single storied)
Time: November 5, 2023;1943 hours IST (user specified)
CHEMICAL DATA:
Chemical Name: TOLUENE
CAS Number: 108-88-3 Molecular Weight: 92.14 g/mol
AEGL-1 (60 min): 67 ppm AEGL-2 (60 min): 560 ppm AEGL-3 (60 min): 3700 ppm
IDLH: 500 ppm LEL: 11000 ppm UEL: 71000 ppm
Ambient Boiling Point: 110.2° C
Vapor Pressure at Ambient Temperature: 0.048 atm
Ambient Saturation Concentration: 49,039 ppm or 4.90%
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

Wind: 5 miles/hour from S at 10 meters
Ground Roughness: urban or forest Cloud Cover: 5 tenths
Air Temperature: 30° C Stability Class: F
No Inversion Height Relative Humidity: 40%
SOURCE STRENGTH:
Leak from hole in vertical cylindrical tank
Flammable chemical escaping from tank (not burning)
Tank Diameter: 3 meters Tank Length: 20 meters
Tank Volume: 141 cubic meters
Tank contains liquid Internal Temperature: 30° C
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Chemical Mass in Tank: 108 tons Tank is 81% full
Circular Opening Diameter: 0.02 meters
Opening is 0 meters from tank bottom
Ground Type: Default soil
Ground Temperature: equal to ambient
Max Puddle Diameter: Unknown
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 2.29 kilograms/min
(averaged over a minute or more)
Total Amount Released: 84.2 kilograms
Note: The chemical escaped as a liquid and formed an evaporating puddle.
The puddle spread to a diameter of 9.2 meters.
THREAT ZONE:
Model Run: Gaussian
Red: less than 10 meters(10.9 yards) --- (3700 ppm = AEGL-3 [60 min])
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Orange: 19 meters --- (560 ppm = AEGL-2 [60 min])
Yellow: 114 meters --- (67 ppm = AEGL-1 [60 min])
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Fig.9
Fig.10
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Fig.10(b)
Fig.10(c)
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Fig.11
Fig.11(a)
20
Fig.12
Fig.12(a)
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Case 2 - Leaking tank, chemical is burning and forms a pool fire
SITE DATA:
Time: November 5, 2023 ;1943 hours ST (user specified)
CHEMICAL DATA:

SOURCE STRENGTH:
Flammable chemical is burning as it escapes from tank
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Max Flame Length: 5 meters
Burn Duration: ALOHA limited the duration to 1 hour
Max Burn Rate: 6.22 kilograms/min
Total Amount Burned: 369 kilograms
Note: The chemical escaped as a liquid and formed a burning puddle.
Fig.13
Fig.14
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Fig.15
Fig.15(b)
Case3: BLEVE,tank explodes and chemical burns in a fireball
SITE DATA:
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Time: November 5, 2023;1943 hours ST (user specified)
CHEMICAL DATA:

SOURCE STRENGTH:
BLEVE of flammable liquid in vertical cylindrical tank
Tank contains liquid
Internal Storage Temperature: 30° C
Percentage of Tank Mass in Fireball: 100%
Fireball Diameter: 267 meters Burn Duration: 16 seconds
THREAT ZONE:
Threat Modeled: Thermal radiation from fireball
Red : 548 meters --- (10.0 kW/(sq m) = potentially lethal within 60 sec)
Orange: 775 meters --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)
Yellow: 1.2 kilometers --- (2.0 kW/(sq m) = pain within 60 sec)
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Fig.16
Fig.16(a)
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Fig.17
Fig.17(a)
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Chapter-4
Observation on different possible diameter

(i) Leak Diameter 0.04m:
Case 1:
SITE DATA:
CHEMICAL DATA:

SOURCE STRENGTH:
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Max Average Sustained Release Rate: 102 kilograms/min
Total Amount Released: 3,943 kilograms
The puddle spread to a diameter of 66 meters.
THREAT ZONE:
Model Run: Heavy Gas
Red : 61 meters --- (3700 ppm = AEGL-3 [60 min])
Fig.18
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Fig.18(a)
Case: 2
SITE DATA:
CHEMICAL DATA:

SOURCE STRENGTH:
30
Max Burn Rate: 377 kilograms/min
Total Amount Burned: 18,729 kilograms
THREAT ZONE:
Threat Modeled: Thermal radiation from pool fire
Yellow: 50 meters --- (2.0 kW/(sq m) = pain within 60 sec)
THREAT AT POINT:
Thermal Radiation Estimates at the point:
Downwind: 204 meters Off Centerline: 76.0 meters
Max Thermal Radiation: 0.0941 kW/(sq m)
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Fig.19
Case 3:
SITE DATA:
CHEMICAL DATA:

32
SOURCE STRENGTH:
THREAT ZONE:
THREAT AT POINT:
Thermal Radiation Estimates at the point:
Downwind: 2.35 kilometers Off Centerline: 1.08 kilometers
Max Thermal Radiation: 0.404 kW/(sq m)
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Fig.20
Fig.20(a)
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(ii) On Diameter = 6m, Length = 40:
Case 1:
SITE DATA:
CHEMICAL DATA:

SOURCE STRENGTH:
Tank Volume: 1,131 cubic meters
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Max Average Sustained Release Rate: 249 kilograms/min
Total Amount Released: 9,077 kilograms
The puddle spread to a diameter of 106 meters.
THREAT ZONE:
Model Run: Heavy Gas
Red : 105 meters --- (3700 ppm = AEGL-3 [60 min])
Yellow: 1.2 kilometers --- (67 ppm = AEGL-1 [60 min])
Fig.21
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Fig.21(b)
Fig.22
37
Fig.22(b)
Fig.23
38
Fig.23(a)
Case2:
SITE DATA:
Time: November 5, 2023 1943 hours ST (user specified)
CHEMICAL DATA:
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) :

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SOURCE STRENGTH:
Max Burn Rate: 804 kilograms/min
Total Amount Burned: 47,256 kilograms
THREAT ZONE:
Threat Modeled: Thermal radiation from pool fire
Yellow: 72 meters --- (2.0 kW/(sq m) = pain within 60 sec)
40
Fig.24
Fig.24(a)
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Case: 3
SITE DATA:
Time: November 5, 2023 1943 hours ST (user specified)
CHEMICAL DATA:

SOURCE STRENGTH:
THREAT ZONE:
42
Red: 1.1 kilometers --- (10.0 kW/(sq m) = potentially lethal within 60 sec)
Orange: 1.5 kilometers --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)
Fig.25
Fig.25(a)
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Chapter-5
Real-Life Example: Toluene Leakage for
Minimal Impact.
SITE DATA:
Location: WAKAYAMA PREFECTURE, JAPAN
Time: December 13, 2023 0128 hours DST (using computer's clock)
CHEMICAL DATA:

Wind: 5 meters/second from NE at 3 meters
Ground Roughness: open country Cloud Cover: 5 tenths
Air Temperature: 24° C Stability Class: D
SOURCE STRENGTH:
Evaporating Puddle (Note: chemical is flammable)
Puddle Area: 5 square meters Puddle Volume: 10 cubic meters
Ground Type: Default soil Ground Temperature: 24° C
Initial Puddle Temperature: 24° C
Max Average Sustained Release Rate: 417 grams/min
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Total Amount Released: 24.7 kilograms
THREAT ZONE:
Model Run: Gaussian
Red : less than 10 meters(10.9 yards) --- (3700 ppm = AEGL-3 [60 min])
Orange: less than 10 meters(10.9 yards) --- (560 ppm = AEGL-2 [60 min])
Fig.26
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Fig.27
Fig.28
Summary of this Example:

The incident, occurring on July 13, 1998, at a chemical factory in Wakayama Prefecture,
Japan, involved the leakage of approximately 200 liters of toluene during the cleaning and
overhaul of a synthetic perfume manufacturing plant. The primary cause was the mistaken
disconnection of a coupling at the upstream side of a block valve instead of the required
downstream side. Contributing factors included the close proximity and identical shapes of
the couplings, coupled with a lack of safety measures addressing human errors.
Although the impact was relatively minor, with one reported injury and a financial cost
below ¥10,000 (5797.2 INR) ,the incident highlights the importance of thorough safety
46
education and continuous review of safety activities. The case emphasizes the need for
preventative measures, even in seemingly routine operations, to enhance safety awareness,
reduce the risk of human error, and prevent potential hazards in chemical manufacturing
facilities.
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Conclusion:
Of Case 1:
The scenarios involving the release of toluene in Kanpur, India, highlight the potential risks
associated with chemical leaks, emphasizing the importance of robust emergency response
strategies and preventive measures. The three distinct scenarios exhibit variations in tank
size, release rates, and threat zones, necessitating tailored responses to address the specific
challenges posed by each incident.
Scenario 1 (Tank: 3m x 20m, Release Rate: 2.29 kg/min):
Threat Zone: The near-field patchiness effects made dispersion predictions less reliable for
short distances, preventing the accurate delineation of threat zones.
Emergency Response: Immediate evacuation within the immediate vicinity, focusing on areas
susceptible to elevated toluene concentrations.
Scenario 2 (Tank: 3m x 20m, Release Rate: 102 kg/min):
Threat Zone: Similar challenges in threat zone prediction due to near-field patchiness,
requiring a dynamic response based on real-time monitoring.
Emergency Response: A more extensive evacuation effort, considering the increased release
rate and potential for larger affected areas.
Scenario 3 (Tank: 6m x 40m, Release Rate: 249 kg/min):
Threat Zone: The Heavy Gas model predicts threat zones with a wider radius, demanding an
extended evacuation and response strategy.
Emergency Response: Comprehensive evacuation planning covering a larger radius,
enhanced firefighting capabilities to handle significant thermal radiation, and establishment
of an incident command center for efficient coordination.
Key Considerations:
The use of dispersion models (Gaussian and Heavy Gas) aids in predicting potential threat
zones, but challenges arise due to near-field patchiness effects.
Evacuation efforts should prioritize areas within the predicted threat zones, with a focus on
protecting individuals from exposure to toluene concentrations.
Emergency response strategies should be adaptable, considering variations in tank size,
release rates, and atmospheric conditions.
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Continuous monitoring of wind patterns, real-time threat assessments, and effective
communication are critical for an adaptive and successful emergency response.
These scenarios underscore the necessity for proactive planning, training, and collaboration
among local authorities, emergency responders, and stakeholders to minimize the impact of
chemical incidents on public safety and the environment.
Of Case 2:
The simulated scenarios of toluene release and combustion in Kanpur, India, emphasize the
critical need for effective emergency response measures in the face of chemical incidents.
Each scenario presents unique challenges and requires tailored strategies for mitigating the
impact on public safety and the environment.
Scenario 1 (Tank: 3m x 20m, Burn Rate: 6.22 kg/min):
Threat Zone: The thermal radiation threat zone is limited, with potentially lethal conditions
extending up to 21 meters from the burning puddle.
Conclusion: Given the relatively small threat zone, emergency responders should focus on
rapid evacuation within the immediate vicinity to ensure the safety of nearby individuals.
Scenario 2 (Tank: 3m x 20m, Burn Rate: 377 kg/min):
Threat Zone: The expanded burn rate results in a larger thermal radiation threat zone,
covering a radius of 31 meters with potentially lethal conditions.
Conclusion: Emergency response efforts should involve a more extensive evacuation plan,
encompassing a larger area affected by the elevated thermal radiation levels.
Scenario 3 (Tank: 6m x 40m, Burn Rate: 804 kg/min):
Threat Zone: The threat zone further increases with a larger tank and higher burn rate,
necessitating evacuation within a 45-meter radius to avoid potentially lethal conditions.
Conclusion: Emergency responders should implement comprehensive evacuation strategies,
considering the larger threat zone and the potential for second-degree burns within a 60-
second timeframe.
Key Considerations for Emergency Response:
Evacuation: Prioritize evacuation efforts based on the predicted threat zones, ensuring the
safety of individuals within the affected areas.
Communication: Establish effective communication channels between local authorities,
emergency responders, and the public to disseminate timely information and instructions.
Coordination: Coordinate an adaptive and dynamic response, considering variations in tank
size, burn rates, and atmospheric conditions.
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Monitoring: Continuously monitor atmospheric conditions, reassess threat zones, and adjust
emergency response strategies accordingly.
Prevention: Emphasize preventive measures to minimize the risk of ignition sources, given
the flammable nature of toluene.
These conclusions underscore the importance of proactive planning, training, and
collaboration to enhance the resilience of the community against potential chemical incidents.
Of Case3:
The scenarios depict the consequences of a Boiling Liquid Expanding Vapor Explosion
(BLEVE) involving toluene in a vertical cylindrical tank. This type of incident poses
significant threats to public safety, necessitating a comprehensive emergency response. The
outcomes are summarized for each scenario:
Scenario 1 (Tank: 3m x 20m, Fireball Diameter: 267m, Burn Duration:

16s):
Threat Zone: The thermal radiation threat zone extends up to 548 meters, with potentially
lethal conditions within 60 seconds.
Conclusion: Emergency responders should focus on a large-scale evacuation plan, covering
an area within 548 meters to mitigate the risk of potentially lethal thermal radiation exposure.

16s):
Threat Zone: Similar to Scenario 1, the thermal radiation threat zone reaches 548 meters,
necessitating evacuation within this radius.
Additional Note: The similarity in threat zones suggests that the tank size and burn duration
are critical factors influencing the extent of the threat.

27s):
Threat Zone: The larger tank size results in an expanded threat zone, reaching up to 1.1
kilometers with potentially lethal conditions.
Conclusion: Emergency response efforts must address the larger threat zone, requiring a more
extensive evacuation plan, public awareness, and coordination with local authorities.
Key Considerations for Emergency Response:
Evacuation Planning: Develop evacuation plans based on the predicted threat zones,
accounting for variations in tank size and burn characteristics.
50
Communication Strategies: Establish robust communication channels for timely
dissemination of information and evacuation instructions.
Public Awareness: Conduct public awareness campaigns to educate residents about
emergency procedures and the potential risks associated with toluene BLEVE incidents.
Emergency Services Coordination: Coordinate with emergency services to ensure a swift
and organized response, emphasizing the need for large-scale evacuations in scenarios with
extended threat zones.
These conclusions underscore the critical importance of proactive emergency preparedness,
community engagement, and coordinated response strategies to effectively mitigate the
impact of toluene BLEVE incidents on public safety and the environment.
51
Summary:-
This report This comprehensive report delves into the nuanced dynamics of toluene
dispersion in the context of chemical engineering environments, with a specific focus on
Kanpur, India. The overarching objective is to assess and compare potential threat zones and
associated hazards in 3 distinct toluene release scenarios, leveraging the advanced simulation
capabilities of the ALOHA software. The study, conducted against the backdrop of an
incident on July 13, 1998, in Wakayama Prefecture, Japan, emphasizes the critical
importance of understanding and mitigating the risks posed by chemical releases.
At the heart of the report is a clear problem: we need to know how to deal with toluene leaks
of different size tanks. The main aim is to learn what factors make these incidents more or
less dangerous. ALOHA software is key here; it's like a virtual lab that helps us understand
and predict what might happen in real-life situations.
We look at three different scenarios, each presenting its own challenges. From the data, we
not only figure out what makes each situation risky but also get insights that can help
emergency teams plan better. The report wraps up stressing that this knowledge, combined
with using ALOHA software, is vital for smart decision-making and preventing problems
before they happen.
At the end, this report is a guide for making sure Kanpur or any similar places are ready to
handle toluene incidents. By digging into the details and using advanced tools like ALOHA,
we're working towards keeping our communities safe from potential risks tied to toluene
use in industries.
52
Reference:
 Crowl, Daniel A. Chemical process safety fundamentals with applications I Daniel A.
Crowl, Joseph F. Louvar. - 2nd ed.
 Shippai Organization.Toluene leakage incident in japan. Retrieved from

https://shippai.org/fkd/en/cfen/CC1200122.html
 OpenAI Chat Community. Retrieved from

https://chat.openai.com/c/4cb3bcd8-4b12-42f6-94a9-7a7600d96772
 The Hindu.(27/12/2022). Retrieved from

https://www.thehindu.com/news/cities/Visakhapatnam/andhra-pradesh-leak-of-toluene-
solvent-might-have-caused-the-fire-accident-says-official/article66311518.ece
 Environmental Protection Agency. CAMEO Aloha Software. Retrieved from

https://www.epa.gov/cameo/aloha-software
 Google Earth.All location Coordinates. Retrieved from

https://earth.google.com/web/@26.49891084,80.26727054,149.47493059a,3306.932408
93d,35y,220.23308857h,0t,0r/data=OgMKATA
53

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Project Report (PRT-S401)

Study of dispersion of toluene through a tank hole via Aloha software

Submitted in partial fulfilment of the requirement for the award of degree of

Bachelor of Technology in Chemical Engineering

Kunal Singh Maurya CSJMA20001390223

Sudhanshu Srivastav CSJMA20001390255

Vaibhav Jaiswal CSJMA20001390259

Under the Guidance of

Dr. Umesh Chandra Sharma

DEPARTMENT OF CHEMICAL ENGINEERING

Kunal Singh Maurya CSJMA20001390223

Priyam Pandey CSJMA20001390238

Sudhanshu Srivastav CSJMA20001390255

Vaibhav Jaiswal CSJMA20001390259

Kunal Singh Maurya CSJMA20001390223

Priyam Pandey CSJMA20001390238

Sudhanshu Srivastav CSJMA20001390255

Vaibhav Jaiswal CSJMA20001390259

Project Supervisor: Dr. Umesh Chandra Sharma

Chapter-1 (Objective and Theory)

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

Case3: BLEVE,tank explodes and chemical burns in a fireball

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

Observation on different possible diameter

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) :

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

Summary of this Example:

Scenario 1 (Tank: 3m x 20m, Release Rate: 2.29 kg/min):

Scenario 2 (Tank: 3m x 20m, Release Rate: 102 kg/min):

Scenario 3 (Tank: 6m x 40m, Release Rate: 249 kg/min):

Scenario 1 (Tank: 3m x 20m, Burn Rate: 6.22 kg/min):

Scenario 2 (Tank: 3m x 20m, Burn Rate: 377 kg/min):

Scenario 3 (Tank: 6m x 40m, Burn Rate: 804 kg/min):

Key Considerations for Emergency Response:

Scenario 1 (Tank: 3m x 20m, Fireball Diameter: 267m, Burn Duration:

Scenario 2 (Tank: 3m x 20m, Fireball Diameter: 267m, Burn Duration:

Scenario 3 (Tank: 6m x 40m, Fireball Diameter: 536m, Burn Duration:

Key Considerations for Emergency Response:

 Shippai Organization.Toluene leakage incident in japan. Retrieved from

 OpenAI Chat Community. Retrieved from

 The Hindu.(27/12/2022). Retrieved from

 Environmental Protection Agency. CAMEO Aloha Software. Retrieved from

 Google Earth.All location Coordinates. Retrieved from

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