Process location decisions - Revision history

Ezhuang at 04:46, 6 February 2016

2016-02-06T04:46:22Z

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	=Location Selection Factors=		=Location Selection Factors=
	A plant's site is chosen based on several factors. These include:<sup>1,2</sup>		A plant's site is chosen based on several factors. These include:<sup>1,2,5</sup>

	'''1. Raw material supply:''' The source and price of raw materials is one of the most important factors that determine the location of a plant. Facilities that produce chemicals in bulk are usually located close to the source of raw material if the costs of shipping the product is less than the costs of shipping the feed. For example, ethylene production is growing in the Middle East since cheap ethane from natural gas is readily available. Oil refineries tend to be located near areas with high population since it is expensive to transport the oil.		'''1. Raw material supply:''' The source and price of raw materials is one of the most important factors that determine the location of a plant. Facilities that produce chemicals in bulk are usually located close to the source of raw material if the costs of shipping the product is less than the costs of shipping the feed. For example, ethylene production is growing in the Middle East since cheap ethane from natural gas is readily available. Oil refineries tend to be located near areas with high population since it is expensive to transport the oil.

Ezhuang at 04:46, 6 February 2016

2016-02-06T04:46:11Z

← Older revision		Revision as of 04:46, 6 February 2016
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	[4] R.T. Turton, R.C. Bailie, W.B. Whiting, J.A. Shaeiwitz, ''Analysis, Synthesis, and Design of Chemical Processes'', Prentice Hall: Upper Saddle River, 2003.		[4] R.T. Turton, R.C. Bailie, W.B. Whiting, J.A. Shaeiwitz, ''Analysis, Synthesis, and Design of Chemical Processes'', Prentice Hall: Upper Saddle River, 2003.

			[5] R.W. Schmenner, Look Beyond the Obvious in Plant Location website. https://hbr.org/1979/01/look-beyond-the-obvious-in-plant-location. January 1979. Accessed February 2016.

Ezhuang: /* Conclusion */

2016-02-06T04:37:23Z

Conclusion

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	=Conclusion=		=Conclusion=

			The location and layout of a plant can greatly impact its economic and operational success. Factors such as cost minimization, distribution, room for expansion, and safety of the plant operators and local community play important roles in the site decision. The location should be obtained before design of the details of the process.

	=References=		=References=

Ezhuang: /* Plant Layout */

2016-02-06T04:29:49Z

Plant Layout

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	'''7. Safety:''' Escape routes for workers need to be in place at each level in process buildings. Blast walls must isolate equipment that pose hazards to confine potential explosions.		'''7. Safety:''' Escape routes for workers need to be in place at each level in process buildings. Blast walls must isolate equipment that pose hazards to confine potential explosions.

	First, a conceptual flowsheet for the process is developed. The types of equipment and their connections with each other is described in a process flow diagram (PFD). ~~After approval,~~ the PFD is translated into a piping and instrumentation ~~diagram~~ (P&ID) ~~that list all equipment,~~ the ~~spares, and show pipe diameters and material, etc~~.<sup>3</sup> Three-dimensional visualization are the layouts are then carried out with cardboard cutouts of the equipment outlines or rectangular and cylindrical blocks. When a layout of the major process units has been decided, drawings of the plan and elevation are made, and design of the structural steelwork and foundations are done. Computer-aided design has also become increasingly popular.<sup>1,4</sup>		First, a conceptual flowsheet for the process is developed. The types of equipment and their connections with each other is described in a process flow diagram (PFD). Before the PFD is translated into detailed piping and instrumentation diagrams (P&ID) the layout of the process units must be planned.<sup>2,3</sup> Scale drawings are made to show the relationships between storage space and process equipment based on the flow of materials and people, and on future expansion. Three-dimensional visualization are the layouts are then carried out with cardboard cutouts of the equipment outlines or rectangular and cylindrical blocks. When a layout of the major process units has been decided, drawings of the plan and elevation are made, and design of the structural steelwork and foundations are done. Computer-aided design has also become increasingly popular.<sup>1,2,4</sup>

	=Environmental Considerations=		=Environmental Considerations=

Ezhuang: /* Location Selection Factors */

2016-02-06T04:26:36Z

Location Selection Factors

← Older revision		Revision as of 04:26, 6 February 2016
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	=Location Selection Factors=		=Location Selection Factors=
	A plant's site is chosen based on several factors. These include:<sup>1</sup>		A plant's site is chosen based on several factors. These include:<sup>1,2</sup>

	'''1. ~~Location with respect to market~~:''' If the plant ~~produces high-volume and low-cost products, such as cement and fertilizer, it may be better~~ to ~~situate~~ the ~~plant closer to~~ the ~~primary market since transportation cost~~ is ~~a large fraction~~ of the ~~sales price~~. If the ~~product~~ is ~~low-volume and~~ high~~-cost, like pharmaceuticals, then the benefits of being closer~~ to the ~~primary market may not be there~~.		'''1. Raw material supply:''' The source and price of raw materials is one of the most important factors that determine the location of a plant. Facilities that produce chemicals in bulk are usually located close to the source of raw material if the costs of shipping the product is less than the costs of shipping the feed. For example, ethylene production is growing in the Middle East since cheap ethane from natural gas is readily available. Oil refineries tend to be located near areas with high population since it is expensive to transport the oil.

	'''2. ~~Raw material supply~~:''' ~~The location also depends on~~ the ~~availability~~ and ~~price of raw material. Facilities that produce chemicals in bulk are usually located close~~ to the ~~source of raw material if~~ the ~~costs of shipping the product~~ is ~~less than the costs~~ of ~~shipping~~ the ~~feed~~. ~~For example, ethylene production is growing in~~ the ~~Middle East since cheap ethane from natural gas~~ is ~~readily available. Oil refineries tend to be located near areas with~~ high ~~population since it is expensive~~ to ~~transport~~ the ~~oil~~.		'''2. Location with respect to market:''' If the plant produces high-volume and low-cost products, such as cement and fertilizer, it may be better to situate the plant closer to the primary market since transportation cost is a large fraction of the sales price. If the product is low-volume and high-cost, like pharmaceuticals, then the benefits of being closer to the primary market may not be there.

	'''3. Transport facilities:''' Facilities should be close to at least two major forms of transportation, whether that be road, rail, waterway, and/or seaport.		'''3. Transport facilities:''' Facilities should be close to at least two major forms of transportation, whether that be road, rail, waterway, and/or seaport.
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	'''10. Political and strategic considerations:''' Government sometimes gives capital grants, tax concessions, and other incentives to encourage plants to be built in specific areas. Companies can also globalize and take advantage of areas with preferential tariff agreements.		'''10. Political and strategic considerations:''' Government sometimes gives capital grants, tax concessions, and other incentives to encourage plants to be built in specific areas. Companies can also globalize and take advantage of areas with preferential tariff agreements.


	=Site Layout=		=Site Layout=

Ezhuang: /* Plant Layout */

2016-02-06T04:23:03Z

Plant Layout

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	'''7. Safety:''' Escape routes for workers need to be in place at each level in process buildings. Blast walls must isolate equipment that pose hazards to confine potential explosions.		'''7. Safety:''' Escape routes for workers need to be in place at each level in process buildings. Blast walls must isolate equipment that pose hazards to confine potential explosions.

	First, a conceptual flowsheet for the process is developed. The types of equipment and their connections with each other is described in a process flow diagram (PFD). After approval, the PFD is translated into a piping and instrumentation diagram (P&ID) that list all equipment, the spares, and show pipe diameters and material, etc.<sup>2</sup> Three-dimensional visualization are the layouts are then carried out with cardboard cutouts of the equipment outlines or rectangular and cylindrical blocks. When a layout of the major process units has been decided, drawings of the plan and elevation are made, and design of the structural steelwork and foundations are done. Computer-aided design has also become increasingly popular.<sup>1,3</sup>		First, a conceptual flowsheet for the process is developed. The types of equipment and their connections with each other is described in a process flow diagram (PFD). After approval, the PFD is translated into a piping and instrumentation diagram (P&ID) that list all equipment, the spares, and show pipe diameters and material, etc.<sup>3</sup> Three-dimensional visualization are the layouts are then carried out with cardboard cutouts of the equipment outlines or rectangular and cylindrical blocks. When a layout of the major process units has been decided, drawings of the plan and elevation are made, and design of the structural steelwork and foundations are done. Computer-aided design has also become increasingly popular.<sup>1,4</sup>

	=Environmental Considerations=		=Environmental Considerations=

Ezhuang: /* References */

2016-02-06T04:22:49Z

References

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	[1] G.P. Towler, R. Sinnott, ''Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design'', Elsevier, 2012.		[1] G.P. Towler, R. Sinnott, ''Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design'', Elsevier, 2012.

	[2] L.T. ~~Biegler~~, I.E. ~~Grossmann, A.W. Westerberg~~, ''~~Systematic Methods of~~ Chemical ~~Process Design~~'', ~~Prentice~~-~~Hall~~: ~~Upper Saddle River~~, ~~1997~~.		[2] M.S. Peters, K.D. Timmerhaus, ''Plant Design and Economics for Chemical Engineers'', 5th Ed., McGraw-Hill: New York, 2003.

	[3] R.T. ~~Turton~~, R.C. ~~Bailie~~, W.~~B. Whiting, J.A. Shaeiwitz~~, ''~~Analysis, Synthesis, and Design~~ of Chemical ~~Processes~~'', Prentice Hall: Upper Saddle River, ~~2003~~.		[3] L.T. Biegler, I.E. Grossmann, A.W. Westerberg, ''Systematic Methods of Chemical Process Design'', Prentice-Hall: Upper Saddle River, 1997.

	[4] M.S. ~~Peters~~, K.D. ~~Timmerhaus~~, ''~~Plant~~ Design ~~and Economics for~~ Chemical ~~Engineers~~'', ~~5th Ed., McGraw-Hill~~: ~~New York~~, 2003.		[4] R.T. Turton, R.C. Bailie, W.B. Whiting, J.A. Shaeiwitz, ''Analysis, Synthesis, and Design of Chemical Processes'', Prentice Hall: Upper Saddle River, 2003.

Ezhuang: /* References */

2016-02-06T04:22:02Z

References

← Older revision		Revision as of 04:22, 6 February 2016
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	[3] R.T. Turton, R.C. Bailie, W.B. Whiting, J.A. Shaeiwitz, ''Analysis, Synthesis, and Design of Chemical Processes'', Prentice Hall: Upper Saddle River, 2003.		[3] R.T. Turton, R.C. Bailie, W.B. Whiting, J.A. Shaeiwitz, ''Analysis, Synthesis, and Design of Chemical Processes'', Prentice Hall: Upper Saddle River, 2003.

			[4] M.S. Peters, K.D. Timmerhaus, ''Plant Design and Economics for Chemical Engineers'', 5th Ed., McGraw-Hill: New York, 2003.

Ezhuang at 04:10, 6 February 2016

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← Older revision		Revision as of 04:10, 6 February 2016
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	'''3. Operation convenience:''' Process units that are attended to frequently should be placed with convenient access. Valves, heads, and sample heads should be placed where operators can easily access. If the plant anticipates replacement of equipment, space must be allowed for removal and installation.		'''3. Operation convenience:''' Process units that are attended to frequently should be placed with convenient access. Valves, heads, and sample heads should be placed where operators can easily access. If the plant anticipates replacement of equipment, space must be allowed for removal and installation.

	'''4. Maintenance convenience:''' Equipment that requires maintenance should be in a location with easy access, and should have sufficient space for the maintenance tasks.		'''4. Maintenance convenience:''' Equipment that requires maintenance should be in a location with easy access, and should have sufficient space for the maintenance tasks. For example, shell-and-tube exchangers need space so that tube bundles can be removed for cleaning and repair.

	'''5. Future expansion:''' The layout should be planned to conveniently allow for future expansion of processes. Pipe racks should have space for future piping, and pipes should be oversized to allow for more flow in the future.		'''5. Future expansion:''' The layout should be planned to conveniently allow for future expansion of processes. Pipe racks should have space for future piping, and pipes should be oversized to allow for more flow in the future.
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	'''7. Safety:''' Escape routes for workers need to be in place at each level in process buildings. Blast walls must isolate equipment that pose hazards to confine potential explosions.		'''7. Safety:''' Escape routes for workers need to be in place at each level in process buildings. Blast walls must isolate equipment that pose hazards to confine potential explosions.

	First, a conceptual flowsheet for the process is developed. The types of equipment and their connections with each other is described in a process flow diagram (PFD). After approval, the PFD is translated into a piping and instrumentation diagram (P&ID) that list all equipment, the spares, and show pipe diameters and material, etc.<sup>2</sup> ~~Layouts~~ are then ~~visualized~~ with cardboard cutouts of the equipment outlines or rectangular and cylindrical blocks. When a layout of the major process units has been decided, drawings of the plan and elevation are made, and design of the structural steelwork and foundations are done. Computer-aided design has also become increasingly popular.<sup>1</sup>		First, a conceptual flowsheet for the process is developed. The types of equipment and their connections with each other is described in a process flow diagram (PFD). After approval, the PFD is translated into a piping and instrumentation diagram (P&ID) that list all equipment, the spares, and show pipe diameters and material, etc.<sup>2</sup> Three-dimensional visualization are the layouts are then carried out with cardboard cutouts of the equipment outlines or rectangular and cylindrical blocks. When a layout of the major process units has been decided, drawings of the plan and elevation are made, and design of the structural steelwork and foundations are done. Computer-aided design has also become increasingly popular.<sup>1,3</sup>

	=Environmental Considerations=		=Environmental Considerations=
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	[2] L.T. Biegler, I.E. Grossmann, A.W. Westerberg, ''Systematic Methods of Chemical Process Design'', Prentice-Hall: Upper Saddle River, 1997.		[2] L.T. Biegler, I.E. Grossmann, A.W. Westerberg, ''Systematic Methods of Chemical Process Design'', Prentice-Hall: Upper Saddle River, 1997.

			[3] R.T. Turton, R.C. Bailie, W.B. Whiting, J.A. Shaeiwitz, ''Analysis, Synthesis, and Design of Chemical Processes'', Prentice Hall: Upper Saddle River, 2003.

Ezhuang at 04:03, 6 February 2016

2016-02-06T04:03:21Z

← Older revision		Revision as of 04:03, 6 February 2016
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	=Location Selection Factors=		=Location Selection Factors=
	A plant's site is chosen based on several factors. These include:<sup>[1]</sup>		A plant's site is chosen based on several factors. These include:<sup>1</sup>

	'''1. Location with respect to market:''' If the plant produces high-volume and low-cost products, such as cement and fertilizer, it may be better to situate the plant closer to the primary market since transportation cost is a large fraction of the sales price. If the product is low-volume and high-cost, like pharmaceuticals, then the benefits of being closer to the primary market may not be there.		'''1. Location with respect to market:''' If the plant produces high-volume and low-cost products, such as cement and fertilizer, it may be better to situate the plant closer to the primary market since transportation cost is a large fraction of the sales price. If the product is low-volume and high-cost, like pharmaceuticals, then the benefits of being closer to the primary market may not be there.
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	The process units and buildings need to be arranged in such a way that allows for the most economical flow of materials and people. Furthermore, dangerous processes need to be a safe distance from other buildings, and the layout should be planned to allow for future expansion.		The process units and buildings need to be arranged in such a way that allows for the most economical flow of materials and people. Furthermore, dangerous processes need to be a safe distance from other buildings, and the layout should be planned to allow for future expansion.

	Process units are usually laid out first in an arrangement that allows for smooth flow of materials between the process steps. The distance between equipment is usually at least 30 m. Next, the location of the principal ancillary buildings are sited as to minimize the time that it takes the workers to travel between buildings. Administrative offices and laboratories are located away from hazardous processes. Control rooms are next to the processing equipment. Utility buildings are located as to minimize piping between the process units. Storage is placed between the loading and unloading facilities and next to the process units that they serve. Tanks containing hazardous material are placed at least 70 m from the plant. An example of a typical site plan is shown below.<sup>[1]</sup>		Process units are usually laid out first in an arrangement that allows for smooth flow of materials between the process steps. The distance between equipment is usually at least 30 m. Next, the location of the principal ancillary buildings are sited as to minimize the time that it takes the workers to travel between buildings. Administrative offices and laboratories are located away from hazardous processes. Control rooms are next to the processing equipment. Utility buildings are located as to minimize piping between the process units. Storage is placed between the loading and unloading facilities and next to the process units that they serve. Tanks containing hazardous material are placed at least 70 m from the plant. An example of a typical site plan is shown below.<sup>1</sup>

	[[File:Site Location.png\|400px\|thumb\|center\|A typical site layout.<sup>[1]</sup>]]		[[File:Site Location.png\|400px\|thumb\|center\|A typical site layout.<sup>[1]</sup>]]
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	=Plant Layout=		=Plant Layout=
	The main factors that are considered when planning the layout of the plant are listed below.<sup>[1]</sup>		The main factors that are considered when planning the layout of the plant are listed below.<sup>1</sup>

	'''1. Economic considerations (construction and operating costs):'''		'''1. Economic considerations (construction and operating costs):'''
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	'''7. Safety:''' Escape routes for workers need to be in place at each level in process buildings. Blast walls must isolate equipment that pose hazards to confine potential explosions.		'''7. Safety:''' Escape routes for workers need to be in place at each level in process buildings. Blast walls must isolate equipment that pose hazards to confine potential explosions.

	First, a conceptual flowsheet for the process is developed. The types of equipment and their connections with each other is described in a process flow diagram (PFD). After approval, the PFD is translated into a piping and instrumentation diagram (P&ID) that list all equipment, the spares, and show pipe diameters and material, etc.<sup>[2]</sup> Layouts are then visualized with cardboard cutouts of the equipment outlines or rectangular and cylindrical blocks. When a layout of the major process units has been decided, drawings of the plan and elevation are made, and design of the structural steelwork and foundations are done. Computer-aided design has also become increasingly popular.		First, a conceptual flowsheet for the process is developed. The types of equipment and their connections with each other is described in a process flow diagram (PFD). After approval, the PFD is translated into a piping and instrumentation diagram (P&ID) that list all equipment, the spares, and show pipe diameters and material, etc.<sup>2</sup> Layouts are then visualized with cardboard cutouts of the equipment outlines or rectangular and cylindrical blocks. When a layout of the major process units has been decided, drawings of the plan and elevation are made, and design of the structural steelwork and foundations are done. Computer-aided design has also become increasingly popular.<sup>1</sup>

	=Environmental Considerations=		=Environmental Considerations=
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	Wastes comprise mainly of by-products, unused reactants, and off-specification product produced by misoperation. Leaking seals and flanges, and spills and discharges also emit waste. Material is also discharged in emergency situations. Instead of considering how to treat or manage waste, designers should start by tackling the source and find ways to minimize the production of waste.		Wastes comprise mainly of by-products, unused reactants, and off-specification product produced by misoperation. Leaking seals and flanges, and spills and discharges also emit waste. Material is also discharged in emergency situations. Instead of considering how to treat or manage waste, designers should start by tackling the source and find ways to minimize the production of waste.

	The process of designing waste management systems are: (1) source reduction, (2) waste stream recycle, (3) waste treatment to reduce environmental impact, and (4) disposal that is legally sound. Source reduction can be achieved by reducing the concentration of impurities in the feed, protecting catalysts and adsorbents from contaminants, eliminating the use of extraneous materials, increasing recovery from separation, and improving the quality of the fuel by switching to cleaner-burning fuel. Unused feed can be recycled, and off-specification products can be reprocessed. In integral processes, the waste of one process is used as the feed for another. By-products can also be sold to another company for use as raw material. Tighter control systems, alarm, and interlocks can reduce misoperation of process unit.<sup>[1]</sup>		The process of designing waste management systems are: (1) source reduction, (2) waste stream recycle, (3) waste treatment to reduce environmental impact, and (4) disposal that is legally sound. Source reduction can be achieved by reducing the concentration of impurities in the feed, protecting catalysts and adsorbents from contaminants, eliminating the use of extraneous materials, increasing recovery from separation, and improving the quality of the fuel by switching to cleaner-burning fuel. Unused feed can be recycled, and off-specification products can be reprocessed. In integral processes, the waste of one process is used as the feed for another. By-products can also be sold to another company for use as raw material. Tighter control systems, alarm, and interlocks can reduce misoperation of process unit.<sup>1</sup>

	=Conclusion=		=Conclusion=
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	=References=		=References=
	[1] G.P. Towler, R. Sinnott, ''Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design'', Elsevier, 2012.		[1] G.P. Towler, R. Sinnott, ''Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design'', Elsevier, 2012.

			[2] L.T. Biegler, I.E. Grossmann, A.W. Westerberg, ''Systematic Methods of Chemical Process Design'', Prentice-Hall: Upper Saddle River, 1997.