plant design & economic4

8/17/2019 Plant Design & Economic4

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Plant Design

General Site Consideration


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Outline

Plant location and siteselection

Site Lay-OutPlant Lay-OutUtilities

Environmental Consideration


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Plant location and Selection

The location of the plant canhave a crucial eect on thepro!ta"ility of a pro#ect and the

scope for future e$pansion%& suita"le site must "e found fora ne' pro#ect including the site

and e(uipment layout planned


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)actors must "e considered 'henselecting a suita"le site for ne'pro#ect*plant

+% Location, 'ith respect to the maretingarea.

/% 0a' material supply.

1% Transport facilities.

2% &vaila"ility of la"or.

3% &vaila"ility of utilities4 'ater, fuel,po'er.


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)actors must "e considered 'henselecting a suita"le site for ne'pro#ect*plant

5%

&vaila"ility of suita"le land.6% Environmental impact, including

e7uent disposal.

8% Local community considerations.

9% Climate.

+:% Political and strategic considerations%


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Marketing area;aterials that are produced in "ul

(uantities, where the cost ofthe product per metric ton isrelatively low and the cost oftransport is a signicant to thesales price, the plant should "elocated close to the primary maret%

This consideration is much less

important for low-volume


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Raw MaterialsPlants that produce "ul chemicals

are "est located close to the source

of the ma#or ra' material, as longas the costs of shipping productare not greater than the cost ofshipping feed%


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Transport& site should "e selected that is close

to at least two major forms of

transport 0oad transport is is suita"le for local

distribution from a central'arehouse%

0ail transport is usually cheaper forthe long-distance transport of bulkchemicals%


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Availability of abor La"or 'ill "e needed for construction

of the plant and its operation%

Silled construction 'orers areusually "rought in from outside thesite area%

Un-silled la"or availa"le locally, andla"or suita"le for training to operatethe plant%


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!tilities "#ervices$ The plant must "e located near a sourceof water of suita"le (uality%

Process 'ater may "e dra'n from a river,

from 'ells, or purchased from a localauthority%

The cooling 'ater re(uired can "e taenfrom a river or lae, or from the sea%

A competitively priced fuel must "eavaila"le on site for steam and po'ergeneration


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%nvironmental &mpact and %'uent(isposal

Consideration must "e given to the

di)culties and cost of disposal of'aste product% The disposal of to$ic and harmful

e7uents 'ill "e covered "y localregulations, and the appropriateauthorities must be consulted%

&n environmental impact assessmentshould "e made for each new


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ocal +ommunity +onsiderationsPlants should generally "e sited so asnot to be upwind of residential

areas%On a ne' site, the local community

must "e a"le to provide adequatefacilities for the plant personnel


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and "#ite +onsiderations$#u)cient suita"le land must "e

availa"le for the proposed plant and

for future e$pansion% The land should ideally "e at, welldrained, and have suita"le load-bearing characteristics%

A full site evaluation should "emade to determine the need forpiling*foundations%

.articular care must "e taen 'hen


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+limate&dverse climatic conditions at a site

'ill increase costs%

&"normally lo' temperatures require the additional insulation and specialheating for e(uipment and pipe runs%

#tronger structures are needed at

locations su"#ect to high 'inds orearth(uaes


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.olitical and #trategic+onsiderations

Capital grants, ta$ concessions, andother inducements are often given bygovernments to direct ne'investment to preferred locations

@n a glo"ali=ed economy, there may

be an advantage to "e gained "ylocating the plant 'ithin an area 'ithpreferential tari agreements


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Site Layout

The process units and ancillary"uildings should "e laid out to give themost economical Ao' of materialsand personnel around the site%

Ba=ardous processes must "e locatedat a safe distance from other"uildings%

Consideration must also "e given tothe future e*pansion of the site


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Site Layout

The ancillary "uildings and servicesre(uired on a site, in addition to themain "uilding unit4

+% Storage for ra' materials andproducts4 tan farms and'arehouses.

/% ;aintenance 'orshops.

1% Stores, for maintenance andoperating supplies.

2% La"oratories for process (ualitycontrol


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Site Layout

The ancillary "uildings and servicesre(uired on a site, in addition to themain "uilding units4

5% Utilities4 steam "oilers, compressedair, po'er generation, refrigeration,transformer stations.

6% E7uent disposal plant

8% O?ces for general administration.

9% Canteens and other amenity"uildings, such as medical centers.


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Site Layout

The process units are normally sited!rst and arranged to give a smoothAo' of materials through the variousprocessing steps, from ra' materialto !nal product storage%

Process units are normally spaced atleast 1:m apart. greater spacing may"e needed for ha=ardous processes%

&dministration o?ces andla"oratories, in 'hich a relatively

large num"er of people 'ill "e


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Site Layout

Control rooms are normally locatedad#acent to the processing units, "utthose 'ith potentially ha=ardousprocesses may have to "e sited at asafer distance%

&ccess roads to each "uilding areneeded for construction and foroperation and maintenance

Utility "uildings should "e sited togive the most economical run of

pipes to and from the process units%


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Site Layout

The main storage areas should "eplaced "et'een the loading andunloading facilities and the processunits they serve%

Storage tans containing ha=ardousmaterials should "e sited at least6:m from the site "oundary%


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Site Layout


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Plant Layout

The economic constructionand e?cient operation of aprocess unit 'ill depend on

how well the plant ande(uipment speci!ed on the

process Ao'sheet is laid out%


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Plant Layout

The principal factors to beconsidered/

+% Economic considerations

./% The process re(uirements.

1% Convenience of operation.

2% Convenience of maintenance.3% Safety.

5% )uture e$pansion.

6% ;odular construction


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Plant Layout

+ost The cost of construction can "e

minimi=ed "y adopting a layout thatgives the shortest run of connecting

pipe "et'een e(uipment%

.rocess RequirementsElevated the "ase of e(uipments to

provide the necessary net positivesuction head to a pump%


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Plant Layout

0perationE(uipment that needs to have

fre(uent operator attention should "e

located convenient to the controlroom%

alves, sample points, andinstruments should "e located atconvenient positions and heights%


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Plant Layout

0perationSu?cient 'oring space and

headroom must "e provided to allo'

easy access to e(uipment% @f it is anticipated that e(uipment 'ill

need replacement, then su?cientspace must "e allo'ed to permitaccess for lifting e(uipment%


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Plant Layout

MaintenanceBeat e$changers need to "e sited so

that the tu"e "undles can "e easily

'ithdra'n for cleaning and tu"ereplacement%

essels that re(uire fre(uentreplacement of catalyst or pacingshould "e located on the outside of"uildings%

E(uipment that re(uires dismantling

for maintenance, such as


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Plant Layout

#afetylast 'alls may "e needed to isolate

potentially ha=ardous e(uipment and

con!ne the eects of an e$plosion%&t least t'o escape routes for

operators must "e provided fromeach level in process "uildings%


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Plant Layout

.lant %*pansionE(uipment should "e located so that

it can "e conveniently tied in 'ith

any future e$pansion of the process%Space should "e left on pipe racs for

future needs, and service pipesshould "e oversi=ed to allo' forfuture re(uirements%


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Plant Layout

The advantages of modularconstruction/

+% @mproved (uality control.

/% 0educed construction cost.1% Less need for silled la"or on site.

2% Less need for silled personnel on

overseas sites%


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Plant Layout

The disadvantages of modularconstruction/

+% Bigher design costs.

/% ;ore structural steel 'or.1% ;ore Aanged connections.

2% Possi"le pro"lems 'ith assem"ly, on

site.


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Plant Layout

1eneral +onsiderations for .lantayoutOpen, structural-steel'or "uildings are

normally used for process e(uipment%

Closed "uildings are used for processoperations that re(uire protection from

the 'eather, for small plants, or forprocesses that re(uire ventilation 'ithscru""ing of the vent gas%


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Plant Layout

1eneral +onsiderations for .lantayout

The arrangement of the ma#or items ofe(uipment often follo's the se(uencegiven on the process Ao'sheet

Columns and vessels arranged in ro's

The ancillary e(uipment, such as heat

e$changers and pumps, positionedalong the outside%


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Plant Layout


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Plant Layout


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Utilities

The utilities is used for the ancillary servicesneeded in the operation of any productionprocess4

Electricity.

Steam, for process heating. Cooling 'ater.

ater for general use.

Deminerali=ed 'ater. Compressed air.

@nert-gas supplies.

0efrigeration.


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Utilities

%lectricity The po'er re(uired for

electrochemical processes, motor

drives, lighting, and general use may"e generated on site, "ut 'ill moreusually "e purchased from the localsupply company%

The voltage at 'hich the supply istaen or generated 'ill depend onthe demand


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Utilities

%lectricity Local su"stations step the po'er

do'n to 13 to 59 for medium

voltage transmission and then to 2 to+3 local distri"ution lines%

Transformers at the plant are used tostep do'n the po'er to the supplyvoltages used on site


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Utilities

#team The steam for process heating is

usually generated in 'ater tu"e

"oilers, using the most economicalfuel availa"le%

The energy costs on a large site can"e reduced if the electrical po'erre(uired can "e generated on siteand the e$haust steam from thetur"ines used for process heating


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Utilities

+ooling 2aterFatural and forced-draft cooling

to'ers are generally used to provide

the cooling 'aterSea 'ater, or "racish 'ater, can "e

used at coastal sites %

@f the am"ient temperature andhumidity are high, cooling 'atersystem 'ill "e less eective


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Utilities

2ater for 1eneral !se The 'ater re(uired for general purposes

on a site 'ill usually "e taen from thelocal mains supply, unless a cheaper

source of suita"le (uality 'ater isavaila"le from a river, lae, or 'ell%

(eminerali3ed 2ater

Used 'here pure 'ater is needed forprocess use and as "oiler feed 'ater%


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Utilities

Refrigeration0efrigeration is needed for processes

that re(uire temperatures "elo'those that can "e economicallyo"tained 'ith cooling 'ater%

)or temperatures do'n to around+:oC, chilled 'ater can "e used% )orlo'er temperatures, do'n to -1:oC,salt "rines %

apor compression refrigeration

machines are normally used%


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Utilities

+ompressed AirCompressed air is needed for general

use and for the pneumatic controllersthat are usually used for chemicalplant control%

&ir is normally distri"uted at a mainspressure of 5 "ar %

0otary and reciprocating single-stageor t'o-stage compressors are used%

@nstrument air must "e dry and cleanfree from oil %


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Utilities&nert 1ases& large (uantity of inert gas is re(uired for

the inert "laneting of tans and forpurging%

Can "e manufactured on site in an airli(uefaction plant or purchased as li(uid intaners%

%'uent (isposal )acilities are re(uired at all sites for the

disposal of 'aste materials 'ithout creatinga pu"lic nuisance

nv ronmen a


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nv ronmen aConsideration

+onsideration must be given to+% &ll emissions to land, air, and 'ater.

/% aste management.

1% Smells.2% Foise.

3% isual impact.

5% &ny other nuisances.6% The environmental friendliness of

the products


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2aste Minimi3ation The hierarchy of 'aste management

approaches4

+% Source reduction4 Dont mae the'aste in the !rst place% This is the"est practice%

2" #ec$cle4 )ind a use for the 'astestream%

3" %reatment 4 0educe the severity ofthe environmental impact%


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2aste Minimi3ation

& techni(ue that is sometimes used for'aste minimi=ation is the !ve-step revie'4

&dentify waste components for

regulatory impact, &dentify waste streams for si3e and

economic impact,

ist the root causes of the wastestreams, ist and analy3e modications to

address the root causes,

.rioriti3e and implement the best


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2aste Management The follo'ing techni(ues can "e

considered4

+% Dilution and dispersion./% Discharge to foul 'ater se'er


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2aste Management The follo'ing techni(ues can "e

considered4

3% iological treatment4 activatedsludge and other processes.

5% @ncineration on land or at sea.

6% Land!ll at controlled sites.8% Sea dumping


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Bome or due to /9*++*/:+/ erian gagasan dan pertim"angan untu

pendirian pa"ri "er"ahan "au minyasa'it H


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