special task-plant layout-final report

8/2/2019 Special Task-Plant Layout-Final Report

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Special Task-Plant layout

March 11th

, 2010

Genius Solutions


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Genius Solutions

SECTION 10Name: Muktar Bashir

Bentham Rep: Dr Steve Hall

Initial grade: B

Changes made to original document:Bold and italics in document

Changes to plant layout attached to A1 Sheet

Number Problem Changes

1 Referencing

-Medical facility

-Transporation and access

Added

2 Size ofaccommodation,medical

facility, control room,Security

centre, no shifts considered

therefore where too large

Revised with shifts considered

3 The number of employees

wasnt consistent with the

economic appraisal report

Number of employees revised

4 Facilities dimension table

adjusted

This has now been considered

5 Flowsheet referred to in Revised


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SUMMARYThis report presents the considerations made in preparing the plant layout based on Just Genius

Solutions flowsheet, and the final drawing produced having taken into account issues relating to

safety and economics.

The total land mass is 300m by 300m, this includes BOC plant and around outside the vinyl

acetate plant where fire station, parking and banks or other facilities are located.

The dimensions of the plant are 100m by 180m.

The surface area for the proposed Vinyl acetate plant is 18000 m2, which comprises of 10800m2 for

the process units and 7200 m2

for facilities.

Potential for 30% expansion of the plant has been considered, with areas identified for potential

expansion labelled on the diagram.

Reactors have been identified as the most hazardous plant items and have been given a 16 metre

clearance from other process units. Other items have been spaced according to guidance from

literature.(J.C.Mecklenburg)


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Introduction

The purpose of this report is to give detailed information for the drawing of a plant layout of a vinyl acetate

plant. The plant layout is constructed from genius solutions flowsheet provided in chemcad and considering

sustainability criteria and other factors(weather conditions, safety e.t.c).

It involves the spatial arrangement of equipment within the steel structure or building of a plant and

considering interconnections through pipes and ducts as well as transportation links. An optimal layout has

to be able to ensure operability, adequete safety and a cost effective design. The main and ancillary units

are located based on health, safety, cost and technical criteria this includes the utilities and buildings. The

number of employees needed to run the plant and expansion of the whole plant has been considered in this

report. Allocation of plant equipments location and buildings was based on their respective functions, alsoemergency routes are located to limit accidents on property. The layout is constructed based on footprints and

dimension of each process unit, buildings and all other facilities present in the plant.

Plant Layout Objectives

Designing Storage facilities for the plant.

Isolation of harzardous areas.

Piping distances-Reducing the cost of piping and pumping.

Safety of personnel and staff by providing suitable location of central buildings. Raw materials get to be separated from the products.

The criteria for allocation and planning should meet up with the objectives: future expansion and modification

of current plant constructed has been accounted for which is usually at about 20-30% allowance.

Every major plant item will be listed in tabular form (inclusive of items on the ChemCAD flow sheet and other

newly added items) and each equipment item or unit will be given a unique code or named accordingly. A top

view drawing of the Vinyl acetate plant site and a drawing of the site from the southern side shall be

implemented and is shown in An A1 sheet: top view and side view drawing of Vinyl acetate plant layout. As

we are looking from top down and from the side, the process units, buildings and storage tanks shall be

represented by circular and rectangular shapes. Main roads, side roads and pathways are also shown and

indicated by the key on the right hand side of the diagram


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plant , process water, raw

materials,steam)

Wind speeds are low around

25km/h

unlikely to affect local community

Low cost of land Wind loads calculated for

equipment typical of location

Safety of inhabitants not a

problem because of the site being

in the outskirts of town

It is an already established

industrial area(market)

Though rainfall is prominent but

unlikely to be a setback

The dimension of the Land is 300m by 300m, which is 90000m2.

Site methodology

The plant layout is constructed based on block methodology arrangement which groupes large blocks of like

characteristics of facilities, utilities or equipment collectively. Usual blocks are mostly grouped as followsstorage tanks, utilities, central buildings, process areas e.t.c. , with the approach of allowing segregation of

different risk types into separate blocks.

Optimal site/ plant layout is achieved by the following steps:

The process units have been arranged to give a smooth flow of materials through the various

processing steps from raw material to final product storage.

A decision of the location of principal buildings on site has been made.

Hazardous processes occurring (such as in the reactor) have been located a safe distance away


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A 753MW Power Plant from the Coryton refinery run by coryton energy will provide both steam and power to

run the plant. Oxygen will be provided from a BOC Plant nearby while other raw materials will be imported and

some from Hull, saltend Ethylene plant.

Effluent collected on the plant will be used in for waste water treatment, this includes heavies and light ends.

Sewage obtained from accommodation is dealt with through two different methods, disposal in waste water

treatment and storage in self-treatment storage.

Fire Station

A fire station will be located Just 100m outside the plant in order to ensure speedy access in case of a fire

emergency.

Medical Facility

A medical facility will have to be provided on site to ensure plant workers are continually in good health. This

will be located alongside the accommodation.

To obtain this footprint it is assumed that no more than 10 workers will need medical facilities at the same

time. For larger scale medical emergencies evacuation to hospitals will take place.

The total footprint will be obtained by multiplying 15 workers(including staff) by the area requirement of one

worker(10m2)(J.C.Mecklenburg).

15 x 10m2

= 150m2

This gives a foot print of 15m by 10m with the height of the facility to be 4m.

Administration and Accomodation Building


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should face north in order to avoid direct sunlight shining onto instruments. Otherwise, lights may not be

visible on a panel face. It is assumed that only 3 operators at any one time will be present in the control room.The operators shall work 2shifts a day morning to afternoon and afternoon to night. The total footprint

required is obtained through multiplication of the number of workers/operators at any one time by the area

required for one operator (this includes monitors and control equipment used). The area required for one

operator (including monitors and control equipment) is estimated at 20m2. The calculation of total footprint is

shown below: 3 20m2= 60m2Therefore, this gives a footprint of 20m by 3m with height of the control room

at 4m. (J.C.Mecklenburg).

Laboratory

The laboratory is essential because thats where the purity of products and other experimentation take place,

it is located in the safe area. The laboratory is used to analyse the composition of the feed (raw materials),

intermediates and products for use in the vinyl acetate process. The minimum area requirement in a

laboratory is 20m2per employee. It is assumed that up to 3 employees shall be using the laboratory at the

same time and hence, the footprint is as calculated below: 3 20m2= 60m2. Their shifts are rotated every 3

days.Therefore, this gives a footprint of 10m by 10m with height of the laboratory facility at 4m.(J.C.Mecklenburg).

Workshop

Materials, tools and apparatus required for plant equipment, maintenance and other repairs are obtained

from the work shop. Safety is also important to consider as all hazardous material shall be stored in the work

shop as well as the machinery required for use within the plant. The minimum area required for the workshop

is 20m2 per employee. An assumption is made that up to 4 employees shall be using the work shop at the sametime and hence, the footprint is as calculated below: 4 20m2= 80m2Hence, a footprint of 20m by 4m is

obtained with height of the laboratory facility at 4m. (J.C.Mecklenburg).


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medical facility 5

Maintenance 9

Total Employees 60

Plant Expansion

At this stage of the plant layout provision of future modification and expansion has been made, they are

considered in every part of the layout and safe options have been made in the event that modifications are

likely. The percentage of land used which is 70% gives room for expansion of the plant and facilities. The

recommended section, the reaction zone, can therefore be easily accommodated.

An allowance for the possibility of future expansion and process and facility modifications of about 30% has

been made.

Emergency and safety

Safety of all employees and of the whole plant is vital, as well as lost of any one of the two cost a lot to reclaim.

Plant units are separated at least 15-30metres at least to avoid spreading of fire to the whole plant. High risk

units( reactor and compressors) are grouped together and are separated from other process units by 20

metres to compromise safety and cost of piping and pumping. The reactor is isolated in blast proof walls with

self closing doors.

In case of emergency, the fire and ambulance station will be located in such a way that it would not be

affected by a major fire and so that it has good access to all parts of the factory to enable emergency action


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Also with regard to roads, the main roads should be 10m wide, side roads should be 7.5m wide and pedestrian

pathways/mini roads should be 2m wide(CCPS).

There will be a designated parking area for vehicles waiting to load or unload, as well as for car parks for

personnel and visitors, which will be in a safe area. The parking area will hold 80 cars; for 60 employees and 20

for visitors.

The typical area for a parking space is 2.6m by 5.5m, therefore the footprint of one parking space is 14.3 m2(1)

.

Multiplying this by 20 gives a footprint of 286 m2, since not all employees will have a car majority use Company

buses. An allowance of 50 m2 will be set for cars to move in and out of the parking spaces. Therefore the total

footprint of the parking area is 336m2.Though itll not be shown in the layout because it is situated just

outside the plant entrance.(CCPS)

(J.C.Mecklenburg). (Phoenix development

6)

Equipment Layout

The layout and spacing of equipment pieces are crucial to the plant layout plan. To reduce the possible risk of

explosions, release and spread of toxic substances, and the spread of fire and their respective consequences,

the distances between the buildings/plant items have been thoroughly considered. The Full flowsheet used is

in the appendix A2.

Reactors

The reactor in the Vinyl acetate plant comprise of the fluidised bed reactor. They pose hazards due to their

operating conditions of high temperature and pressure.


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Pumps

It has been decided that in order to reduce the piping and pumping cost, each pump linked to a particular unit

will be located alongside that unit.

Clearances between pumps or between pumps and piping should be at least 1.2m for small pumps (less than

18kW) and 1.5m to 2m for larger pumps.

Compressors

The compressors used in the plant are centrifugal compressors. They should be installed to facilitate

dismantling and reassembly. Generally in the layout of compressors, a minimum space between compressor,

between rows of compressor and at the end of each row subject to any special maintenance considerations. Aspace of 1.8 m is allowed between compressors and they are surrounded by walls.

Storage tanks

There will be 13 storage tanks: 6 for vinyl acetate produced, 2 for acetic acid , 2 ethylene, one for each oxygen,

P-hydroquinone, ethyl acetate and 3 water tanks. The storage tanks will be located not very far from processequipments. The inhibitor storage thank will be located near the column and reactor to reduce pumping and

piping cost. However, the storage tanks containing the final products have flammable material inside them,

therefore a minimum spacing distance of 152 m is recommended between these tanks and centres of


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Flare Diameter=2m

Dimensions and Footprint Area

In order to draw the plant layout, all the necessary dimensions of each unit have been calculated from the

detailed and ancillary designs. Also facility dimensions are included to pace up drawing of the whole plant

layout.


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12

Facilities length(m) width(m) Height(m) footprint(m^2)

Accomodation 10 3 4 30

Administrative facility 14 10 4 140

Control room 20 3 4 60

Security centre 10 1 4 10

Laboratory 10 10 4 100

Refractory 10 3 3 30

Workshop 20 4 4 80

Parking 20 14.3 4 486

medical facility 15 10 4 150

Total Area 1086


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Detailed Main Equipment Dimensions

Main equipments height/length(m) diameter

(m)

Footprint(m2)

Reactor(10) 9.62 3.35 8.81

Scrubber(13) 18.58 3.45 9.35

Absorber 15.00 3.00 7.08

Azeotropic Column 1(18) 30.00 9.14 65.67


acetic acid recovery(14) 21.86 4.43 15.41

distillation Column(29) 11.40 1.25 1.23

distillation column(22) 13.29 2.13 3.58

total area 114.71

Ancillary Design Dimensions

Ancillary equipments case(height/length)(m) diameter(m) footprint(m

2

)

Condenser(inside column) 2.78 10.25 82.52

Decanter 4.10 1.30 5.33


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Reboiler 4.20 4.10 17.22

condenser 4.10 0.33 1.37

heat exchanger 4.20 1.06 4.44

reflux drum 4.20 1.14 4.79

pump 0.50 0.50 0.25

Stripper column 13.50 4.50 15.90

reboiler 6.05 0.30 0.07

pump 0.20 0.20 0.04

Compressor 2.80 2.80 7.84

heat exchanger 4 5.12 0.91 4.66


Flash column 2 2.85 4.70 17.35

Flash column 11 3.20 2.76 5.98

pump 1 0.20 0.20 0.04

pump 2 0.20 0.20 0.04

reboiler 5.12 0.43 2.19

condenser 5.12 0.97 4.99

decanter 1.11 0.37 0.41


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Discussion and Conclusion

When arranging specific process equipment and facilities, safety and emergency has been taken into

consideration. With regards to this, one of the most important facilities is the fire station which is within

100m of the plant, Not shown in the diagram. On site there is a medical facility which is purpose built to

deal with the rare event of disaster striking the plant, such as fire or explosion.

The storage tanks have been assigned a distance of 3 metres from the relevant process units. The other

storage tanks are located closer to access roads for easy charging or unloading of material.

The Azeotropic distillation Column vessel number 22 was unreasonably large with a diameter of

9.14m compared to other columns. The main reason for this is the very high flow rate entering the tank.

Since there was space to accommodate such a vessel on the site it was kept as it was sized in the ancillarydesign.

Reactors have been identified as more hazardous and have been given a 20 metre clearance, in order

to comply with safety and loss prevention guidelines, so that any fire in a reactor doesnt spread to other

units and cause widespread damage

The plant safe area includes accommodationand parking spaces, a medical facility, buildings for

administration and security, a control room and a laboratory. The parking spaces are located outside the

plant therefore not shown in Plant layout diagram.The control room is in an area where a good view of

the process area is possible, but not too close to reactors.The control room is considerably small given its importance to the plant. This is because the sizing of

this is based purely on the workers spatial requirements as opposed to how many pieces of

instrumentation will be in the control room. At the north-eastern corner of the plant, the flare is located.


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Bibliography and References

1- J. C. Mecklenburgh, 1973, Plant Layout,IchemE

2- J. C. Mecklenburgh, 1973, Plant Layout:A guide to layout of process plant and sites,IchemE

3-Cheryl Baker and Joseph Natale, 2003, Center for Chemical Process Safety

4- Center for Chemical Process Safety (CCPS), August 2003, Guidelines for Facility Siting and Layout

5-KLM TECHNOLOGY GROUP: Flare Selection and Sizing (Engineering Design Guideline) -http://kolmetz.com/pdf/EDG/ENGINEERING%20DESIGN%20GUIDELINE-%20Flare%20Rev1.1.pdf

(Accessed 12-March-2011)

6-Parking Requirements Guidelines, City of Pheonix development services department-

http://www.phoenix.gov/DEVSERV/prkguide.pdf(Accessed 1-March-2011)

7-KLM TECHNOLOGY GROUP-Storage Tank Selection and Sizing (ENGINEERING DESIGN GUIDELINE)-

http://kolmetz.com/pdf/EDG/ENGINEERING_DESIGN_GUIDELINE__storage_tank_rev_1.pdf(Accessed 7-March-2011)

8- FLARES-http://www.gasflare.org/pdf/Flare_Type.pdf(20-March-2011)
http://kolmetz.com/pdf/EDG/ENGINEERING%20DESIGN%20GUIDELINE-%20Flare%20Rev1.1.pdfhttp://kolmetz.com/pdf/EDG/ENGINEERING%20DESIGN%20GUIDELINE-%20Flare%20Rev1.1.pdfhttp://www.phoenix.gov/DEVSERV/prkguide.pdfhttp://www.phoenix.gov/DEVSERV/prkguide.pdfhttp://kolmetz.com/pdf/EDG/ENGINEERING_DESIGN_GUIDELINE__storage_tank_rev_1.pdfhttp://kolmetz.com/pdf/EDG/ENGINEERING_DESIGN_GUIDELINE__storage_tank_rev_1.pdfhttp://kolmetz.com/pdf/EDG/ENGINEERING_DESIGN_GUIDELINE__storage_tank_rev_1.pdfhttp://www.phoenix.gov/DEVSERV/prkguide.pdfhttp://kolmetz.com/pdf/EDG/ENGINEERING%20DESIGN%20GUIDELINE-%20Flare%20Rev1.1.pdf


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A1: PLANT LAYOUT-SEE DRAWINGS SECTION A1 SHEET

A2:GENIUS SOLUTIONS FLOWSHEET-NEXT PAGE


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A3:MAP OF LOCATION


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A4:FULL TABLE OF ALL DATA

Main equipments height/length(m) diameter (m) Footprint(m^2)

Reactor 9.62 3.35 8.81

Scrubber 18.58 3.45 9.35

Absorber 15.00 3.00 7.08



acetic acid recovery(14) 21.86 4.43 15.41

distillation Column(29) 11.40 1.25 1.23

distillation column(22) 13.29 2.13 3.58

total area 114.71

Experts Ancillary equipments Actual Length/height(m) case(height/length)(m) diameter(m) width


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Jente Condenser(inside column) 2.78 10.25

Decanter 4.10 1.30

Reboiler(same as condenser) - 4.10 1.30 -

Pump 0.20 0.20 0.20

Will Flash column 18.90 18.90 6.33


Heat exchanger 23 3.03 5.08 0.84

pump 0.20 0.20 0.20

Priyan heat exchanger 12 5.00 4.20 0.80

Reboiler30 4.80 4.03 0.61

Condenser30 6.10 5.12 0.30

Muktar Heat exchanger 31 2.44 2.05 1.16

Heat exchanger 27 2.44 2.05 1.94

compressor 0.76 1.52 0.76 1.52

kushal Reboiler 4.88 4.10 1.01


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condenser 1.83 1.53 0.33

Erik Reboiler 5.00 4.20 4.10

condenser 4.88 4.10 0.33

heat exchanger 5.00 4.20 1.06

reflux drum 4.20 4.20 1.14

pump 0.50 0.50 0.50

Rittick Stripper column 13.50 13.50 4.50

reboiler 7.20 6.05 0.30

pump 0.20 0.20 0.20

Compressor 1.40 2.80 1.40 2.80



Flash column 2 2.85 2.85 4.70

Flash column 11 3.20 3.20 2.76

Adeola pump 1 0.20 0.20 0.20


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pump 2 0.20 0.20 0.20

reboiler 6.10 5.12 0.43

condenser 6.10 5.12 0.97

decanter 1.11 1.11 0.37

Footprints of ancillary corresponding to equipments in table above

footprint(m^2)

82.52

5.33

5.33

0.04

31.47

4.24

4.24

0.04

3.34


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2.48

1.55

2.38

3.98

2.31

4.14

0.51

17.22

1.37

4.44

4.79

0.25

15.90

0.07

0.04


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7.84

4.66

2.10

17.35

5.98

0.04

0.04

2.19

4.99

0.41


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