Plant Design

General Site Consideration

Outline
Plant

location and site

selection
Site Lay-Out
Plant Lay-Out
Utilities
Environmental Consideration

Plant location and Selection

The

location of the plant can

have a crucial effect on the
profitability of a project and the
scope for future expansion.
A suitable site must be found for
a new project including the site
and equipment layout planned

Plant location and Selection

Factors must be considered when
selecting a suitable site for new
project/plant
1. Location, with respect to the marketing
area;
2. Raw material supply;
3. Transport facilities;
4. Availability of labor;
5. Availability of utilities: water, fuel,
power;

Plant location and Selection

Factors must be considered when
selecting a suitable site for new
project/plant
6. Availability of suitable land;
7. Environmental impact, including
effluent disposal;
8. Local community considerations;
9. Climate;
10. Political and strategic considerations.

Plant location and Selection

Marketing area
Materials that are produced in bulk
quantities, (cement, mineral acids,
and fertilizers) where the cost of
the product per metric ton is
relatively low and the cost of
transport is a significant to the
sales price, the plant should be
located close to the primary market.
This consideration is much less
important for low-volume

Plant location and Selection

Raw Materials
Plants that produce bulk chemicals
are best located close to the source
of the major raw material, as long
as the costs of shipping product
are not greater than the cost of
shipping feed.

Plant location and Selection

Transport
A site should be selected that is close
to at least two major forms of
transport (road, rail, waterway, or
sea port)
Road transport is is suitable for local
distribution from a central
warehouse.
Rail transport is usually cheaper for
the long-distance transport of bulk
chemicals.

Plant location and Selection

Availability of Labor
Labor will be needed for construction
of the plant and its operation.
Skilled construction workers are
usually brought in from outside the
site area.
Un-skilled labor available locally, and
labor suitable for training to operate
the plant.

Plant location and Selection

Utilities (Services)
The plant must be located near a source
of water of suitable quality.
Process water may be drawn from a river,
from wells, or purchased from a local
authority.
The cooling water required can be taken
from a river or lake, or from the sea.
A competitively priced fuel must be
available on site for steam and power
generation

Plant location and Selection

Environmental Impact and Effluent
Disposal
Consideration must be given to the
difficulties and cost of disposal of
waste product.
The disposal of toxic and harmful
effluents will be covered by local
regulations, and the appropriate
authorities must be consulted.
An environmental impact assessment
should be made for each new

Plant location and Selection

Local Community Considerations
Plants should generally be sited so as
not to be upwind of residential
areas.
On a new site, the local community
must be able to provide adequate
facilities for the plant personnel
(schools, banks, housing, and
recreational and cultural facilities).
The local community must also be
consulted about plant water

Plant location and Selection

Land (Site Considerations)
Sufficient suitable land must be
available for the proposed plant and
for future expansion.
The land should ideally be flat, well
drained, and have suitable loadbearing characteristics.
A full site evaluation should be
made to determine the need for
piling/foundations.
Particular care must be taken when

Plant location and Selection

Climate
Adverse climatic conditions at a site
will increase costs.
Abnormally low temperatures require
the additional insulation and special
heating for equipment and pipe runs.
Stronger structures are needed at
locations subject to high winds
(cyclone/hurricane areas) or
earthquakes

Plant location and Selection

Political and Strategic
Considerations
Capital grants, tax concessions, and
other inducements are often given by
governments to direct new
investment to preferred locations
In a globalized economy, there may
be an advantage to be gained by
locating the plant within an area with
preferential tariff agreements

Site Layout
The

process units and ancillary

buildings should be laid out to give the
most economical flow of materials
and personnel around the site.
Hazardous processes must be located
at a safe distance from other
buildings.
Consideration must also be given to
the future expansion of the site

Site Layout
The ancillary buildings and services
required on a site, in addition to the
main building unit:
1. Storage for raw materials and
products: tank farms and
warehouses;
2. Maintenance workshops;
3. Stores, for maintenance and
operating supplies;
4. Laboratories for process quality
control

Site Layout
The ancillary buildings and services
required on a site, in addition to the
main building units:
6. Utilities: steam boilers, compressed
air, power generation, refrigeration,
transformer stations;
7. Effluent disposal plant
8. Offices for general administration;
9. Canteens and other amenity
buildings, such as medical centers;

Site Layout
The

process units are normally sited

first and arranged to give a smooth
flow of materials through the various
processing steps, from raw material
to final product storage.
Process units are normally spaced at
least 30m apart; greater spacing may
be needed for hazardous processes.
Administration offices and
laboratories, in which a relatively
large number of people will be

Site Layout
Control

rooms are normally located

adjacent to the processing units, but
those with potentially hazardous
processes may have to be sited at a
safer distance.
Access roads to each building are
needed for construction and for
operation and maintenance
Utility buildings should be sited to
give the most economical run of
pipes to and from the process units.

Site Layout
The

main storage areas should be

placed between the loading and
unloading facilities and the process
units they serve.
Storage tanks containing hazardous
materials should be sited at least
70m (200 ft) from the site boundary.

Site Layout

Plant Layout
The

economic construction
and efficient operation of a
process unit will depend on
how well the plant and
equipment specified on the
process flowsheet is laid out.

Plant Layout
The principal factors to be
considered:
1. Economic considerations
(construction and operating costs);
2. The process requirements;
3. Convenience of operation;
4. Convenience of maintenance;
5. Safety;
6. Future expansion;
7. Modular construction

Plant Layout
Cost
The cost of construction can be
minimized by adopting a layout that
gives the shortest run of connecting
pipe between equipment.
Process Requirements
Elevated the base of equipments to
provide the necessary net positive
suction head to a pump.

Plant Layout
Operation
Equipment that needs to have
frequent operator attention should be
located convenient to the control
room.
Valves, sample points, and
instruments should be located at
convenient positions and heights.

Plant Layout
Operation
Sufficient working space and
headroom must be provided to allow
easy access to equipment.
If it is anticipated that equipment will
need replacement, then sufficient
space must be allowed to permit
access for lifting equipment.

Plant Layout
Maintenance
Heat exchangers need to be sited so
that the tube bundles can be easily
withdrawn for cleaning and tube
replacement.
Vessels that require frequent
replacement of catalyst or packing
should be located on the outside of
buildings.
Equipment that requires dismantling
for maintenance, such as

Plant Layout
Safety
Blast walls may be needed to isolate
potentially hazardous equipment and
confine the effects of an explosion.
At least two escape routes for
operators must be provided from
each level in process buildings.

Plant Layout
Plant Expansion
Equipment should be located so that
it can be conveniently tied in with
any future expansion of the process.
Space should be left on pipe racks for
future needs, and service pipes
should be oversized to allow for
future requirements.

Plant Layout
The advantages of modular
construction:
1. Improved quality control;
2. Reduced construction cost;
3. Less need for skilled labor on site;
4. Less need for skilled personnel on
overseas sites.

Plant Layout
The disadvantages of modular
construction:
1. Higher design costs;
2. More structural steel work;
3. More flanged connections;
4. Possible problems with assembly, on
site;

Plant Layout
General Considerations for Plant
Layout
Open, structural-steelwork buildings are
normally used for process equipment.
Closed

buildings are used for process

operations that require protection from
the weather, for small plants, or for
processes that require ventilation with
scrubbing of the vent gas.

Plant Layout
General Considerations for Plant
Layout
The arrangement of the major items of
equipment often follows the sequence
given on the process flowsheet
Columns and vessels arranged in rows
The ancillary equipment, such as heat
exchangers and pumps, positioned
along the outside.

Plant Layout

Plant Layout

Utilities
The utilities is used for the ancillary services
needed in the operation of any production
process:
Electricity;
Steam, for process heating;
Cooling water;
Water for general use;
Demineralized water;
Compressed air;
Inert-gas supplies;
Refrigeration;

Utilities
Electricity
The power required for
electrochemical processes, motor
drives, lighting, and general use may
be generated on site, but will more
usually be purchased from the local
supply company.
The voltage at which the supply is
taken or generated will depend on
the demand (transmitted over long
distances at 135, 220, 550, or 750

Utilities
Electricity
Local substations step the power
down to 35 to 69 kV for medium
voltage transmission and then to 4 to
15 kV local distribution lines.
Transformers at the plant are used to
step down the power to the supply
voltages used on site (Most motors
and other process equipment run on
208V 3-phase power, while 120/240V
single phase power is used for

Utilities
Steam
The steam for process heating is
usually generated in water tube
boilers, using the most economical
fuel available.
The energy costs on a large site can
be reduced if the electrical power
required can be generated on site
and the exhaust steam from the
turbines used for process heating
(Combine Heat and Power/Co-

Utilities
Cooling Water
Natural and forced-draft cooling
towers are generally used to provide
the cooling water
Sea water, or brackish water, can be
used at coastal sites (more expensive
materials of construction for HE).
If the ambient temperature and
humidity are high, cooling water
system will be less effective (use air
coolers or refrigeration)

Utilities
Water for General Use
The water required for general purposes
on a site will usually be taken from the
local mains supply, unless a cheaper
source of suitable quality water is
available from a river, lake, or well.
Demineralized Water
Used where pure water is needed for
process use and as boiler feed water.

Utilities
Refrigeration
Refrigeration is needed for processes
that require temperatures below
those that can be economically
obtained with cooling water.
For temperatures down to around
10oC, chilled water can be used. For
lower temperatures, down to -30oC,
salt brines (NaCl and CaCl2).
Vapor compression refrigeration
machines are normally used.

Utilities
Compressed Air
Compressed air is needed for general
use and for the pneumatic controllers
that are usually used for chemical
plant control.
Air is normally distributed at a mains
pressure of 6 bar (100 psig).
Rotary and reciprocating single-stage
or two-stage compressors are used.
Instrument air must be dry and clean
(free from oil).

Utilities
Inert Gases
A large quantity of inert gas is required for
the inert blanketing of tanks and for
purging.
Can be manufactured on site in an air
liquefaction plant or purchased as liquid in
tankers.
Effluent Disposal
Facilities are required at all sites for the
disposal of waste materials without creating
a public nuisance

Environmental
Consideration
Consideration must be given to
1. All emissions to land, air, and water;
2. Waste management;
3. Smells;
4. Noise;
5. Visual impact;
6. Any other nuisances;
7. The environmental friendliness of
the products

Environmental Consideration
Waste Minimization
The hierarchy of waste management
approaches:
1. Source reduction: Dont make the
waste in the first place. This is the
best practice.
2. Recycle: Find a use for the waste
stream.
3. Treatment: Reduce the severity of
the environmental impact.

Environmental Consideration
Waste Minimization
A technique that is sometimes used for
waste minimization is the five-step review:
Identify waste components for
regulatory impact.
Identify waste streams for size and
economic impact.
List the root causes of the waste
streams.
List and analyze modifications to
address the root causes.
Prioritize and implement the best

Environmental Consideration
Waste Management
The following techniques can be
considered:
1. Dilution and dispersion;
2. Discharge to foul water sewer (with
the agreement of the appropriate
authority);
3. Physical treatments: scrubbing,
settling, absorption, and
adsorption;

Environmental Consideration
Waste Management
The following techniques can be
considered:
5. Biological treatment: activated
sludge and other processes;
6. Incineration on land or at sea;
7. Landfill at controlled sites;
8. Sea dumping (now subject to tight
international control).

Home Work due to 29/11/2012

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Operatibility