CHEMICAL PLANT DESIGN

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Plant location and site selection
Plant layout design
2 Plant location and site selection
The geographical location of any industrial plant has strong
influence on the success of the project.
Considerable care must be exercised in selecting the plant site, and
many different factors must be considered.
Primarily, the plant should be located where the minimum cost of
production and distribution can be obtained, but other factors, such
as room for expansion and safe conditions for plant system as well
as the surrounding community, are also important.
3 Plant Location Factors

1. Raw materials availability

2. Markets
3. Energy availability
4. Climate conditions
5. Transportation facilities
6. Water supply
7. Waste disposal
8. Labor supply
9. Taxation and legal restrictions
10. Site Characteristics
11. Flood and fire protection
12. Community factors
 Three factors are usually considered the most important. These are the
location of the markets and raw materials and the type of transportation
4 to be used.
Transportation:
The transport of materials and products to and from the plant will be an
overriding consideration in site selection. If practicable , a site should be
selected that is close to at least two major forms of transport : road , rail,
waterway (canal or river ), or a sea port .The least expensive method of
shipping is usually by water; the most expensive is by truck.
Raw materials:
The availability and price of suitable raw materials will often determine
the site location. Propylene is the major raw material for the
manufacture of Acrylic acid , hence the plant can be located near any
plant producing propylene . It will reduce transportation and storage
costs.
Location of markets:
Consumer products often are delivered in small shipment to a large
number of customers. Since acrylic acid acts as a raw material for the
production of consumer goods like paints, plastics, pharmaceutical
binders etc. , it is always advantages for the plant to be situated in a
industrial area .
 Water :
5 water is needed by every processing plant for a number of different
purposes. Potable water is needed for drinking and food preparation. The
plant site must have an adequate amount of each type of water at all
times of the
Climatic Conditions:
Adverse climatic conditions at a site will increase costs. Stronger
structures will be needed at locations subject to high winds or earthquake.
Pollution and Ecological Factors:
All industrial processes produce waste products , and full consideration
must be given to the difficulties and cost of their disposal. The disposal of
toxic and harmful effluents will be covered by local regulations, and the
Appropriate authorities must be consulted during the initial site survey to
determine the standards must be met.
Site Conditions:
An ideal chemical plant site is above the flood plain, flat, has good
drainage , a high soil- bearing capability , and consists of sufficient land
for the proposed plant and for future expansion.
6 Plant Layout

After the process flow diagrams are completed and before detailed
piping, structural, and electrical design can begin, the layout of
process units in a plant and the equipment within these process units
must be planned.
This layout can play an important part in determining construction
and manufacturing costs, and thus must be planned carefully with
attention being given to future problems that may arise. Since each
plant differs in many ways and no two plant sites are exactly alike,
there is no one ideal plant layout. However, proper layout in each case
will include arrangement of processing areas, storage areas, and
handling areas in efficient coordination and with regard to such
factors as:
7 Plant Layout Cont’d

1. New site development or addition to previously developed site

2. Type and quantity of products to be produced
3. Type of process and product control
4. Operational convenience and accessibility
5. Economic distribution of utilities and services
6. Type of buildings and building-code requirements
7. Health and safety considerations
8. Waste-disposal requirements
9. Auxiliary equipment
10.Space available and space required
11.Roads and railroads
12.Possible future expansion
8 The economic construction and efficient operation of a process
depend on how well the plant and equipment specified on the
process flow sheet is laid out. The principal factors to be considered
are:
• Costs: construction and operating costs.
• The process requirement.
• Convenience of operation.
• Convenience of maintenance
• Safety.
• Future expansion
• Modular construction
9 Costs :
The cost of construction can be minimized by adopting a layout
that gives the shortest run of connecting pipe between equipment,
and the least amount of structural steel works.
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. Sufficient working space and headroom must be
provided to allow easy access to equipment's.
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.
10 Plant expansion :
Equipment's should be located so that it can be
conveniently tied in with future expansion of the process.
Modular construction :
In recent years there has been a move to assemble sections
of plant at the plant manufacturer’s site. These modules will
include the equipment ,structural steel , piping and
instrumentation. The modules are then transported to the
plant site, by road or sea.

General consideration :
Open, structural steelwork , building are normally used for
process equipment; closed buildings are only used for
process operations that require protection from the weather.
11 Typical Master Plot Plan
12 List of plant units in a typical layout

. Process units/ unit operations

· Tank farms
· Loading and unloading facilities
· Flares
· Power, boilers and incinerators
· Cooling towers
· Substations, large electrical switch yards
· Central control houses
· Warehouses
· Analytical laboratories
· Incoming utility metering and block systems
· Fire hoses, fixed monitors, reservoirs and emergency fire pumps
· Waste treatment areas
· Maintenance buildings and areas
· Administrative buildings
13 Storage

Adequate storage facilities for raw materials, intermediate products,

final products, recycle materials, off-grade materials, and fuels are
essential to the operation of a process plant.
A supply of raw materials permits operation of the process plant
regardless of temporary procurement or delivery difficulties.
Storage of intermediate products may be necessary during plant
shutdown for emergency repairs while storage of final products
makes it possible to supply the customer even during a plant
difficulty or unforeseen shutdown.
An additional need for adequate storage is often encountered when
it is necessary to meet seasonal demands from steady production.
14 Storage Cont’d
Bulk storage of liquids is generally handled by closed spherical or
cylindrical tanks to prevent the escape of volatiles and minimize
contamination.

Liquids with vapor pressures above atmospheric must be stored in

vapor-tight tanks capable of withstanding internal pressure.

If flammable liquids are stored in vented tanks, flame arresters must

be installed in all openings except connections made below the
liquid level.
15 Storage Cont’d

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 a flexible rubber
or plastic curtain.

Solid products and raw materials are either stored in

weather-tight tanks with sloping floors or in outdoor bins and
mounds. Solid products are often packed directly in bags,
sacks, or drums.
16 Materials Handling
Materials-handling equipment is logically divided into continuous and
batch types, and into classes for the handling of liquids, solids, and gases.

Liquids and gases are handled by means of pumps and blowers; in pipes,
flumes, and ducts; and in containers such as drums, cylinders, and tank
cars.

Solids may be handled by conveyors, bucket elevators, chutes, lift trucks,

and pneumatic systems.

The selection of materials-handling equipment depends upon the cost and

the work to be done.
17 Factors that must be considered in selecting
such equipment include:

1. Chemical and physical nature of material being handled

2. Type and distance of movement of material
3. Quantity of material to be moved per unit time
4. Nature of feed and discharge from materials-handling
equipment
5. Continuous or intermittent nature of materials handling
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