CHAPTER SIX

6.0 SITE AND LOCATION AND PLANT LAYOUT

A suitable site for the alum plant would depend on several factors namely; proximity to the

required feed stock supply, environmental impact of the plant, proximity to the required market

for distribution and operators for handling etc. However, the environmental consideration is by far

the most important factor that must be considered in locating a suitable site.

According to government regulation (Maria, 2003), Alum plants are considered as commercial

plants and ought to be located in industrial zones. However, the location of such plants outside an

industrial area is legal since it does not conflict with public interest, its effluent are biodegradable

and pose less threat to the environment.

The decision to build the plant is made based on a feasibility study. The market for products, the

supply of raw materials, the infrastructural and the recruitment of qualified operators are taken into

consideration. The final result is a cost-benefit calculation based on assumed values (Maria, 2003).

6.1 GENERAL OVERVIEW OF PLANT LAYOUT

Basically, the economic construction and efficient operation of the process units will depend on

how well the plant and equipment specified on the process flow diagram were laid out. The

principal factors to be considered include:

Economic consideration: both initial fabrication and operating cost

Process requirements

Convenience for operation

Convenience for maintenance

Safety

Future expansion
 Modular construction

6.1.1 Cost

The cost of construction can be minimized by adopting a layout that gives the shortest run of

connecting pipes between equipment and the least amount of structural steel work. However, this

will not necessarily be the best arrangement for operation and maintenance.

6.1.2 Process Requirements

Certain process consideration maybe needed, like the elevation of the base of columns, reactor,

tanks to provide the necessary net positive suction head to a pump or the operating head for a

thermosyphon reboiler.

6.1.3 Convenience for Operation

Equipment that needs operators frequent attention should be located conveniently for easy access

like the valves, sample points. Hence, they should be located at suitable position and height

sufficient working space and head room must be provided to allow easy access to equipment.

6.1.4 Convenience for Maintenance

Heat exchangers should be suitably sited, so that the tube bundles can be easily withdrawn for

cleaning and tube replacement. Equipment that requires dismantling for maintenance such as

compressors, pumps and motors, should be place under cover. Equipment that requires frequent

cleaning or replacement like the decanter or the filter should be properly located with enough

clearance to allow for such maintenance.

6.1.5 Safety

Blast walls maybe needed to isolate potentially hazardous equipment and confine the effect of an

explosion. At least two escape routes for operators must be provided from each level in the process

platform.
6.1.6 Future 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 alleys for future needs, and sensitive pipes oversized

should be allowed for future use.

6.1.7 Modular Construction

The modules will include equipment, structural steel, pipe and instrumentation. The advantages of

modular construction or improved quality control, reduced construction cost and lower risk or

hazard potential. While some disadvantages include higher design costs and more slanged

connections.

6.2 PLANT LAYOUT SPECIFICATION

As easily seen in the process flow diagram, the optimal plant layout of minimal area consumption

based on the triglyceride technique of stearic acid production suggest two reactors in series and

feedstock vessels arranged closely for easy introduction into the reactors and ease in operations.

Minimum distance between each main unit = 5m

Total number of main units process plant = 16

Total number of auxillary units (pumps) = 4

Allowable distance for auxillary units = 3m

Safety allowance = 30%

Table 6.1 shows the surface area occupied by each main unit of the process plant in the production

area as calculated in the equipment design of chapter five.