Plant layout Development

In practice, plant layout development is dependent on experience and design insight, and there is no substitute for having the most experienced practitioners for the job. The following outline is aimed at recognizing the information necessary to advance the layout work, and at reviewing the end result. 

The plant layout development normally entails an iterative procedure review and redevelopment of the individual plant area designs and footprints until a satisfactorily balanced overall design is achieved. There may be a few major layout options to consider. Selection of the preferred choice includes attention to ... 

The development section serves as an intermediary between laboratory and industrial scale and operates the pilot plant. A dkect transfer from the laboratory to industrial-scale processes is stiH practiced at some small fine chemicals manufacturers, but is not recommended because of the inherent safety, environmental, and economic risks. Both equipment and plant layout of the pilot plant mirror those of an industrial multipurpose plant, except for the size (typically 100 to 2500 L) of reaction vessels and the degree of process automation. 

The standard requires plant layouts to minimize material travel and handling, synchronize material flow, and optimize value added use of floor space and to use a multidisciplinary approach for developing plant facility and equipment plans. 

The final plant layout combines the various engineering considerations for soil conditions drainage railroad, truck and services access raw materials receiving waste materials removal climate effect on outdoor versus indoor operations and on types of structures prevailing wind direction for vent as well as climiatic moisture corrosion plant expansion and growth access to public, and many other general evaluation points. From these broad considerations the details are developed to suit the particular plant process and the combined effects of the location. 

The acceptability of some industrial and ephemeral development projects such as landfill or mineral extraction may depend upon an ability to restore the landscape after exploitation has been completed. As more rural development projects come to fruition, ecologists will become increasingly involved in resource management to ensure that yields are sustained and to avert the undesirable consequences of development. Some industrial developments and rearranged plant layout schemes will not be complicated, but when ecology studies are needed, the employment of specialist consultants is recommended. 

Technological development and its effect upon plant layout... 

The development of these technologies can be followed in the proceedings of the professional institutions and the many magazines, some available free. You should define the state of technological awareness in the company and consider how this affects the plant layout. 

There have been important world developments in the philosophy of factory operation and they affect plant layouts. 

Several industry standards, codes, and company internal standards were used in developing the information in Table 1.2. These include internal company standards NFPA 30, Flammable and Combustible Liquids Code (Ref. 22) NFPA 59A. Liquefied Natural Gas (Ref. 23) API 2510, Design and Construction of Liquefied Petroleum Gas(LPG) Installations (Ref. 24) iRlnformation IM.2.5.2, Plant Layout and Spacing for Oil and Chemical Plants (Ref. 25), and Factory Mutual 7-44, Spacing of Facilities In Outdoor Chemical Plants (Ref. 26). 

Develop necessary process and design information (Section 3.1). The first step in the analysis is to obtain necessary information in sufficient detail to support the type of evaluation being performed. This can include information about the materials being handled, the process conditions, and other site-specific information such as the type of building construction, occupancy, plant layout, and equipment location. 

Process industry has used the Dow Fire and Explosion Hazard Index (DOW, 1987) and the Mond Index (ICI, 1985) for many years. These indices deal with fire and explosion hazard rating of process plants. Dow and Mond Indices are rapid hazard-assessment methods for use on chemical plant, during process and plant development, and in the design of plant layout. They are best suited to later design stages when process equipment, chemical substances and process conditions are known. 

The usual die used is a crosshead with a 90° angle between the wire line and the extruder body axis (Chapter 17). With this setup, the entire length of the extruder projects sideways from the coating lines. To help melt flow from developing dead spots in the melt channels, 30° or 45° crossheads can be used. They provide a more streamlined interior and the extruder location is better adapted to some plant layouts. They are sometimes preferred when processing PVC because of the streamlining and better control of the melts heat profile. Most dies are subjected to very high internal pressures since the uncommon pressure in the extruder barrel of over 5,000 psi (35 MPa) is required. 

Before proceeding any further with the development of a process design and its associated economics, it will be desirable to consider an overall view of the various functions involved in a complete plant design. Particular emphasis in this discussion will be placed on important health, safety, loss prevention, and environmental considerations. Other items that will be noted briefly include plant location, plant layout, plant operation and control, utilities, structural design, storage, materials handling, patents, and legal restrictions. 

Develop a complete plant layout for the sodium dodecylbenzene sulfonate plant that is described in Chap. 2. Indicate location of instruments, control valves, and panel boards. Provide possibilities for future expansion or revision of the plant. 

Plant layout is one area where real cost control can be exercised because of the impact on material and construction costs as well as on operating efficiency. The final layout, usually developed during the basic engineering stage, requires a high degree of experience and the participation of the entire project team as well as the contractor s specialists and Owner s operations and maintenance personnel. 

The cost-conscious Project Manager with a good feel for costs will usually find cost-saving opportunities in the development of plant layouts. 

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