CHAPTER 1

INTRODUCTION TO
PROCESS PLANT & EQUIPMENT
DESIGN
Chemical Plant Design

The general term plant design includes all engineering

aspects involved in the development of either a new,
modified, or expanded industrial plant.

The chemical engineering technologist will involve in

economic evaluations of new processes, designing
individual pieces of equipment, or developing a plant
layout.

Because of these many design duties, the chemical

engineering technologist is many times referred to as a
design engineering technologist.
Chemical Plant Design

A chemical engineering technologist specializing in the

economic aspects of the design is often referred to as a
cost engineering technologist.

The term process engineering is used in connection with

economic evaluation and general economic analysis of
industrial processes, while process design refers to the
actual design of the equipment and facilities necessary
for carrying out the process.
Plant Improvement

Debottlenecking Plant

Increase Plant Capacity

Increase Plant Efficiency

Decrease Costs

Pollution Minimization
 Debottlenecking Plant
Debottlenecking is the process of identifying specific areas
and/or equipment in oil and gas facilities that limit the flow of
product and optimizing them so that overall capacity in the plant
can be increased.

The first step in a debottlenecking process generally involves

examining the overall operating conditions of a facility.

In many instances this means comparing current operating

parameters and system settings (flow rates, pipe diameters,
pressures, etc.) with the design specifications of process
equipment.

In some situations, eliminating a bottleneck can be as simple as

changing system parameters to match recommended design
values.

Other times, however, the solution may require a bit more time
and effort, such as replacing an entire piece of equipment or
retrofitting it to better match the needs of the facility.
Increase Plant Capacity & Efficiency

Debottlenecking

Reducing plant-wide energy usage

Types of raw material

Types of process

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 Increase Plant Efficiency
Control Scheme Modifications Increase Efficiency of Steam
Generation System at ExxonMobil Gas Plant 2002

In 1998, control scheme modifications were made to the

steam system at ExxonMobils Mary Ann Gas Plant in Mobile,
Alabama, following a system-level energy survey.

Before the modifications, the plant was operated to the boilers

and maximize the output of the main turbine baseload
generator. After the modifications, the plant operated in a
more efficient thermal following mode.

The modifications that were performed reduced steam flow

through the high-to-medium and medium-to-low pressure
reducing stations and into the low-pressure steam condenser.
 Increase Plant Efficiency
Control Scheme Modifications Increase Efficiency of Steam
Generation System at ExxonMobil Gas Plant 2002

These changes have reduced energy consumption by 170

billion Btu, and saved about $375,000 annually, with no
capital investment.

The original control scheme was based on past conditions,

where excess high-pressure steam was provided by waste
heat boilers.

Changes in operating conditions now require production of

high pressure steam from fired boilers.
Increase Plant Efficiency
Increase Plant Efficiency
 Decrease Costs
Reduce preventive maintenance costs - Examine what is
necessary, and what is not necessary

When first purchasing an equipment, ensure you review its

preventive maintenance requirements with the manufacturers
and your subject matter experts, whether those are engineers or
senior maintenance professionals.

You should confirm that all of the suggested preventive

maintenance is actually needed, as unnecessary preventive
maintenance can actually induce equipment failure.
Decrease Costs
For example at one of a chemical plants, pumps were
undergoing preventive maintenance every quarter to prevent
pump failures. This maintenance was actually inducing
premature failure. After engineering performed a detailed
root-cause analysis, a different pump was specified and
preventive maintenance was moved to a yearly event, leading
to better system performance and reduced maintenance
costs.

Therefore, it leads to:

Decreased labor costs

Reduced parts purchases

Increased the efficiency and overall uptime of the system

 Pollution Minimization

Waste

In theory, waste applies to nonproduct output of processes and

discarded products, irrespective of the environmental medium
affected.

Pollution/Pollutants

Pollution and pollutants refer to all nonproduct output, irrespective of

any recycling or treatment that may prevent or mitigate releases to the
environment (includes all media).
 Pollution Minimization
Waste Minimization

Waste minimization initially included both treating waste to minimize its

volume or toxicity and preventing the generation of waste at the source.

The distinction between treatment and prevention became important

because some advocates of decreased waste generation believed that an
emphasis on waste minimization would deflect resources away from
prevention towards treatment.

In the current RCRA biennial report, waste minimization refers to source

reduction and recycling activities and now excludes treatment and
energy recovery.

The Resource Conservation and Recovery Act (RCRA) is the public law that creates the
framework for the proper management of hazardous and non-hazardous solid waste. The law
describes the waste management program mandated by Congress that gave EPA authority to
develop the RCRA program.
 Pollution Minimization
Source Reduction

Source reduction is defined in the Pollution Prevention Act of 1990 as any

practice which:

(1) reduces the amount of any hazardous substance, pollutant, or

contaminant entering any waste stream or otherwise released into the
environment (including fugitive emissions) prior to recycling, treatment,
and disposal

(2) reduces the hazards to public health and the environment associated
with the release of such substances, pollutants, or contaminants.

The term includes equipment or technology modifications, process or

procedure modifications, reformulations or design of products, substitution
of raw materials, and improvements in housekeeping, maintenance,
training, or inventory control.
 Pollution Minimization

Pollution Prevention

Pollution prevention refers to activities to reduce or eliminate

pollution or waste at its source or to reduce its toxicity.

It involves the use of processes, practices, or products that reduce or

eliminate the generation of pollutants and waste or that protect
natural resources through conservation or more efficient utilization.

Pollution prevention does not include recycling, energy recovery,

treatment, and disposal.

Some practices commonly described as in-process recycling may

qualify as pollution prevention.
 Importance of Process Design

Decide on Raw Materials Operating Costs

Decide on Process

Reactor System Capital Costs

Separation System Capital Costs

Recycle System Capital Costs

Heat Integration Scheme Capital Costs

Utilities Operating Costs

Sequence of steps in developing a project

Time sequence
Process identification
Laboratory scale process research
Bench scale investigations
Preliminary economic evaluation
Process development
Mass and energy balance
Detailed process design

Project Steps Site selection

Refined economic evaluation
Design Fixed
Detailed economic evaluation
Engineering flow scheme
Basic design
Detailed construction plan
Detail design
Procurement (locating)
Construction
Startup
 How is Design Practiced
Process Conception
Preliminary Design
Process Concepts
Process Economics Stage Gate
Management decision to go forward
Intermediate Design Management
P&IDs
Ask vendors for prices major pieces of equipment
Reactor, Separators, Utilities, tank farms
Process Economics
Management decision to go forward
Detailed Design
Mechanical Engineering
Equipment + Supports
Piping elevation
Electrical/Power Engineering
Utilities
Process Economics
Management decision to go forward
 Process Creation

Chemical Reaction Routes

Preliminary Database
MSDS (Health and safety info.)
Raw Materials
Reaction Products and Intermediates

Thermo/phys properties (Expts and Predictions)

Heats of Formation
VLE data, solubilities, etc.

Chemical Prices (Chemical Market Reporter)

VLE Vapor liq equalibrium

Operating costs

Selection of Reaction Route to Product

Determine Gross Profitability of Process

Examples:
Vinyl Chloride Manufacture (part of PVC plant)
Process Economics-I

Macro View
Possible Reactions for vinyl chloride production
1) C2H4 (ethylene) + Cl2 C2H3Cl (vinyl Chloride) + HCl
2) C2H2 (acetylene) + HCl C2H3Cl
3) C2H4 + Cl2 C2H4Cl2 C2H3Cl + HCl
4) C2H2 + 2HCl + O2 C2H4Cl2+H2O
C2H4Cl2 C2H3Cl +H2O
C2H2 + 2HCl + O2C2H3Cl +H2O (overall)

5) C2H4 + Cl2 C2H4Cl2

C2H2 + 2HCl + O2 C2H4Cl2+ H2O
2 C2H4Cl2 2C2H3Cl + 2HCl
2C2H4 + Cl2 + O2 2C2H3Cl + H2O (overall)
Gross Profitability Analysis-1
Start With Raw Material Costs and Product Prices
Gross Profitability Analysis-1
Determine the profit to be made gross profit for each
reaction
22/lb(1) +18/lb (0.583)-18/lb(0.449)-11/lb(1.134)=11.94 /lb
Gross Profitability Analysis-2
Overview of Various Reactions

Which one is most profitable?

Reaction 3 is most profitable!

http://nexant.ecnext.com/coms2/summary_0255-3041_ITM
Onion Model of Process Design
 Plant Location

The geographical location of any industrial plant has strong

influence on the success of the project.

Considerable care must be implemented 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 living
conditions for plant operators as well as the surrounding
community, are also important.
 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
 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:
 Plant Layout

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
 Typical Master Plot Plan
x x x x x x x x x x x x x x x x x x x x x x x x
x N

xLandscaped Future Process Area

Area

Picking-plant
processing
Chemical
x Reservoir area (extend lot
Area Neutralizing tanks
200 ft east )

x
Packing
Parking
Area and x
shipping Future
x area Power-point Storage
x
Area Area

x Loading x
Railroad siding x
x
x x x x x x x x x x x x x x x x x x x x x x x x x

ISCO Chemical Company

Ferrous Sulfate Recovery Plant
Master Plot Plan: Scale =10 ft
 List of plant units in a typical layout

Process units
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
 Storage
Suitable 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.
 Storage

Bulk storage of liquids is

generally handled by
closed spherical or
cylindrical tanks to
prevent the escape of
volatiles and minimize
contamination.
 Storage

Liquids with vapor pressures above

atmospheric must be stored in vapor-tight
tanks capable of withstanding internal
pressure.
 Storage

If flammable liquids are

stored in vented tanks,
flame arresters must be
installed in all openings
except connections made
below the liquid level.
 Storage

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.
 Storage

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.
 Materials Handling
Materials-handling equipment is rationally 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 tubes; and in containers
such as drums, cylinders, and tank cars.

Solids may be handled by conveyors,

bucket elevators, lift trucks,
and pneumatic systems.
 Materials Handling Contd
The selection of materials-handling equipment depends
upon the cost and the work to be done.
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
 Utilities
1. In the chemical industries, power is supplied primarily in the
form of electrical energy. Agitators, pumps, blowers,
compressors, and similar equipment are usually operated by
electric motors.

2. When a design engineering technologist is setting up the

specifications for a new plant, a decision must be made on
whether to use purchased power or have the plant set up its
own power unit. It may be possible to obtain steam for
processing and heating as a by-product from the self-
generation of electricity, and this factor may influence the final
decision.

3. Power can be transmitted in various forms, such as mechanical

energy, electrical energy, heat energy, and pressure energy.
The engineering technologist should recognize the different
methods for transmitting power and must choose the ones best
suited to the particular process under development.
 Utilities

4. Steam is generated from whatever fuel is the cheapest, usually

at pressures of 450 psig (3100 kPa) ore more, expanded
through turbines or other prime movers to generate the
necessary plant power, and the exhaust steam is used in the
process as heat. The quantity of steam used in a process
depends upon the thermal requirements, plus the mechanical
power needs, if such a power is generated in the plant.

5. Water for industrial purposes can be obtained from one of two

general sources: the plants own source or a municipal supply.
If the demands for water are large, it is more economical for
the plant to provide its own water source. Such a supply may
be obtained from ground water or surface water sources.
Before a company agrees to go ahead with any new project, it
must ensure itself of a sufficient supply of water for all
industrial, sanitary, and safety demands, both present and
future.
 List of utilities

Compressed Air: Plant and Instrument

Natural Gas
Fire Protection
City and Process Water
Chilled Water
Wastewater
Hot Water Heating
Steam and Condensate
Fuel Handling: Gasoline, Diesel,
Cooling and Tower Water
Motor/Hydraulic/Cutting Oil
Process Gases: N, H2 and CO2
THANK YOU