Chemical Engineering
Plant Design
Lecture 02
Dr. Zakir Khan
Assistant Professor
[email protected] General Design
Consideration
Plant Location
1. Raw materials availability
2. Markets
3. Energy availability
4. Climate
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
Raw Materials Availability
The source of raw materials is the most
important factors
Near location of the raw-materials source
permits considerable reduction in:
Transportation
Storage charges
If requirement of large volumes of raw materials,
so attention should be given to:
Purchased price of the raw materials
Distance from the source of supply
Transportation expenses
Availability and reliability of supply
Purity of the raw materials
Storage requirements
Markets
The location of markets affects:
Cost
of product distribution
Time required for shipping
Markets is an important consideration in
the selection of a plant site:
Advantageous
to buyer
Markets are needed for by-products as
well
Energy Availability
High requirements of power and
steam in industries
Fuel required to supply power and
steam
For Example:
Electrolytic processes require a cheap source
of electricity so;
Plant requires large quantities of coal or oil
Location must be near by large hydroelectric
installations
Location near a source of fuel
Local cost of power can help to
determine whether:
Power should be purchased
or self-generated
Climate
If the plant is located in a cold climate,
costs may be increased:
If the plant is located in hot climate:
Special cooling towers
Air-conditioning equipment may be required
If there is excessive humidity or extremes
of hot or cold weather:
Construction of protective shelters around the
equipment
Serious effect on the economic operation of a
plant
Climate factors must be examined when
selecting a plant site
Transportation Facilities
Rail tracks, roads, and highways are the common
Products and raw materials required transportation facilities.
Possibility of canal, river, lake, or ocean transport must be
considered.
If possible, the plant site should have access to all three types of
transportation or at least two types should be available.
Water
Road
Rail
Air transportation facilities between the plant and the main company
headquarters
Water Supply
The process industries use large quantities of water for;
Cooling
Washing
Steam generation
Raw material.
Plant, must be located, where, water is available
River or lake is preferable
Deep wells are satisfactory if the amount of water required is not too
high
Try to drill several standby wells
Factors considered during choosing water supply:
Temperature
Mineral content
Sand content
Bacteriological content
Cost for supply
Purification
Waste Disposal
Legal restrictions have been placed on the methods for
disposing of waste materials from the process industries
Site selected for a plant should have capacity and
facilities for correct waste disposal.
Attention should be given to potential requirements for
additional waste-treatment facilities
Labor Supply
Labor availability must be examined
Consideration should be given to:
Pay scales
Restrictions on number of hours worked per week
Competing other industries
Productivity of the workers
Welfare of workers
Avoid
Taxation & Legal Restrictions
State and local tax rates:
Property income
Unemployment insurance
Local regulations on:
Building codes
Transportation facilities
Required permits
Flood and Fire Protection
Many industrial plants are located along rivers and there are risks of flood
Before selecting a plant site:
Regional history of natural events of this type should be examined
Protection from losses by fire is another important factor
In case of a major fire, assistance from outside fire departments should be
available
Community Factors
Character and facilities of a community can have quite effect on the
location of the plant
Cultural facilities of the community are important to sound growth
Masjids, libraries, schools, colleges, theaters and other similar
groups, are important for recreation
FFC CLUB
Plant Layout
After the process flow diagrams and before detailed PID
must planned:
Layout of process units in a plant
Equipment within these process units
Plant layout play an important part in determining:
Construction and manufacturing costs
There is no one ideal plant layout, so several problems
may arise
Attention to the storage space and operating equipment
Consideration of the safe operational sequence
Primary layout based on the flow of materials
Three dimensional models
Model of Plant Layout
Plant Operation and Control
Instrumentation
Instruments are used in the chemical industry to measure process variables,
Temperature
Pressure
Density
Viscosity
Specific heat
Conductivity
pH
Humidity
Dew point
Liquid level
Flow rate
Chemical composition
Moisture content..
Automatic control is the normal throughout the chemical industry
Control is achieved through the use of high-speed computers
Control room is used for the indication, recording, and regulation of the
process variables
Instrumentation
Panel boards present a graphical representation
of the process and have the instrument controls
and indicators
Helps to operator
To quickly
become familiar with instrument readings
To rapid location identification of any problem
Maintenance
Many of the problems of maintenance are caused by a lack of original
design and layout of plant and equipment
There should be sufficient space for maintenance work on equipment and
facilities.
Utilities
Power can be transmitted in various forms such as:
Mechanical energy
Electrical energy
Heat energy
Pressure energy.
The engineer should recognize the different methods and chose best one
Decision must be made on whether to use purchased power or have the
plant set up its own power unit
Sources of water (Own or Muncipal)
Storage
Storage facilities are essential for:
Raw materials
Intermediate products
Final products
Recycle materials
Off-grade materials
Fuels
Liquids is generally handled by closed spherical or
cylindrical tanks. Vapor pressure, an important criterion.
Gases are stored at atmospheric pressure in wet or dry
seal gas holders
Solid products and raw materials are either stored in
weather-tight tanks with sloping floors or in outdoor bins
and mounds
Material Handling
Liquids and gases are handled by means of pumps and blowers,
pipes, ducts and in containers such as drums, cylinders.
Solids may be handled by conveyors, bucket elevators, lift trucks,
and pneumatic systems.
Factors that must be considered in selecting equipment include:
1. Chemical and physical nature of material being handled
2. Type and distance of movement of material
3. Quantity of material moved per unit time
4. Continuous or batch nature of materials handling
Materials-handling problems are:
Corrosion
Fire
Heat damage
Explosion
Pollution
Toxicity
He (Allah) Who produces fire for you out of the
green tree so now you kindle fire with the same!
(Al-Quran, Surah Ya-Sin, Verse 80)
THANK YOU
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