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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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Plant location and Selection
)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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Plant location and Selection
)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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Plant location and Selection
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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Plant location and Selection
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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Plant location and Selection
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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Plant location and Selection
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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Plant location and Selection
!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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Plant location and Selection
%nvironmental &mpact and %'uent(isposal
Consideration must "e given to the
di)culties and cost of disposal of'aste product% The disposal of to$ic and harmful
e7uents 'ill "e covered "y localregulations, and the appropriateauthorities must be consulted%
&n environmental impact assessmentshould "e made for each new
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Plant location and Selection
ocal +ommunity +onsiderationsPlants should generally "e sited so asnot to be upwind of residential
areas%On a ne' site, the local community
must "e a"le to provide adequatefacilities for the plant personnel
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Plant location and Selection
and "#ite +onsiderations$#u)cient suita"le land must "e
availa"le for the proposed plant and
for future e$pansion% The land should ideally "e at, welldrained, and have suita"le load-bearing characteristics%
A full site evaluation should "emade to determine the need forpiling*foundations%
.articular care must "e taen 'hen
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Plant location and Selection
+limate&dverse climatic conditions at a site
'ill increase costs%
&"normally lo' temperatures require the additional insulation and specialheating for e(uipment and pipe runs%
#tronger structures are needed at
locations su"#ect to high 'inds orearth(uaes
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Plant location and Selection
.olitical and #trategic+onsiderations
Capital grants, ta$ 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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Environmental Consideration
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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Environmental Consideration
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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Environmental Consideration
2aste Management The follo'ing techni(ues can "e
considered4
+% Dilution and dispersion./% Discharge to foul 'ater se'er
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Environmental Consideration
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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4e*t ecture0peratibility