Process layouts

Consideration of alternatives seeks to ensure that the proposer has considered other feasible options including location, scales, processes, layouts, operating conditions and the no action option. 

Figure 6.49 Typical process layout of a continuous hot dip galvanizing line...

A final example of application and process layout is shown in Figure 15. In this example the process relies on activated carbon to remove color bodies from a recycled glucose intermediary prior to use in the production of confectionary. The glucose containing the color taint must be mildly heated (to about 70° C), so that the normally solid product becomes less viscous and easier to pump. The syrup is... 

The airflow rate does not interfere with the building or the building materials, and usually not with the process. The air distribution may vary a lot, however, if the building and process layout and sometimes the building materials are not chosen with great care. Lamps, ladders, window shutters, cabins, process equipment, etc. are often placed where the ventilation designer did not expect any obstructions. Thus continuous cooperation between the different designers is necessary to prevent mistakes and to facilitate common solutions to this type of problem (see Chapter 8). 

The first step is to determine the types of plant equipment and systems that are to be included in your program. A plant survey of your process equipment should be developed that lists every critical component within the plant and its impact on both production capacity and maintenance costs. A plant process layout is invaluable during this phase of program development. It is very easy to omit critical machines or components during the audit. Therefore, care should be taken to ensure that all components that can limit production capacity are included in your list. 

The spacing recommendations for process layout have been presented in literature as matrixes and lists of the typical minimum distances between different process items (Industrial Risk Insurers (1991) Bausbacher and Hunt (1993) Prugh (1982)). A suitable distance to another process item depends mostly on the safety properties of the process items. The clearance required for maintenance and access determine usually shorter spacings compared to safety clearances. In some references access and maintenance clearances are given separately. Therefore it can be assumed that the average of the recommended equipment spacings is mostly related to the general unsafety of a specific process item. 

Layout spacings are also affected by other factors than safety. The space requirements of maintenance, repair works and proper performing of process operations has to be included into the process layout. Proper spacing around equipment is required to allow easy operation. Enough room should be provided for pipes, supports and foundations as well. 

The D.M.2 gasifier is also based on an indirectly heated gasification process. The heat needed for the gasification stage is introduced into the process by a heat carrier (e.g., spheres of corundum). One possible process layout for hydrogen production based on the staged-reforming process is shown in Fig. 10.4. 

Process layout (= 4000 L production size) in quanties and Vmax... 

Figure 3 Process layout of a membrane steam reformer [21],...

Synthesis gas is compressed to the synthesis pressure, typically ranging from 140 to 220 kg/cm2g and converted into ammonia in a synthesis loop using radial flow synthesis converters, either the two-bed S-200, the three-bed S-300, or the S-250 concept using an S-200 converter followed by a boiler or steam superheater, and a one-bed S-50 converter. Ammonia product is condensed and separated by refrigeration. This process layout is flexible, and each ammonia plant will be optimized for the local conditions by adjustment of various process parameters. Topsoe supplies all catalysts used in the catalytic process steps for ammonia production. 

The process layout for production of propylene from ethylene and butene is shown in Figure 10.7. ... 

The coke formation leads to catalyst fouling. This is solved in the UOP Process by continuously removing a portion of the catalyst and passing this to a separate regenerator. After regeneration by combustion of the coke in air, the catalyst is sent back to the main reactor. In concept this is similar to fluid-cat cracking of refinery stocks. The process layout is illustrated in the Figure 11.7. 

FIGURE 1 Typical solid dosage manufacturing process layout. 

Process Layout, Description, and Observations Sources and Quantities of Pollution Load Generated Existing Treatment Facilities and Additional Requirements Observations on Proposed Treatment Systems Integrated Pollution Prevention Strategy Generation of Options, Screening... 

Aware of all target process layouts for further audit... 

Native soy protein isolate may be produced by ultrafiltration of an aqueous extract of defatted soy bean meal, Q), (5 ). The process layout is shown in Fig. 1. A careful selection of membrane parameters such as flow velocity, pressure drop, temperature, and of the type of membrane and modules is important in order to obtain a bean protein isolate by a direct ultrafiltration of the clarified extract ( 5). The protein isolate has a protein-dry matter ratio higher than 90% (N x 6.25), when using this process. 

The octane number of the gasoline product from the TIGAS process will depend on the process layout. Especially the hydrogen level in the loop will influence the octane number (Fig. 12). The highest research octane numbers observed have been a few numbers lower than those obtained in the MTG process (ref. 9), whereas the motor octane numbers are similar. The reduced octane number, which is the result of the low olefinic content in the gasoline, is the penalty to be paid for the benefits obtained by integration. The size of the penalty will depend on the end use of the product from a TIGAS plant, the octane requirements at the specific location and the extent to which octane improvers are available and acceptable. 

Figure 3.16. Process layout for PVMBR system IV. HE heat exchanger C condenser VP vacuum pump. From Groot et al [3.58], with permission from Springer-Verlag.

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