Reduce Energy Consumption for Material Transfer

This can be done by less handling of materials when the plant layout is designed 

Reaction mass from first reactor is sent to second reactor by gravity flow and likewise from second reactor to third reactor during manufacture of alum by a continuous process. It then flows into the settler/clarifier and finally to evaporator by gravity. 

Obtaining fuel gas from external grid operating under pressure (this will not need a separate gas compressor for feeding to furnace). 

Obtaining raw water from external supply lines operating under pressure and directly feeding into filters/treatment units (this will not need a separate pump for feeding to filters). 

When the ducts and pipelines have larger diameter, the fluid velocity reduces, and consequently, the pressure drop for the same flow rate also reduces. This is also the case when the process units have more cross-sectional area available for flow. Power consumption can be thus reduced by a choice of larger cross section. However, the cost of the pipelines and the equipments may increase with higher size. An optimisation shall be done by considering the total of initial capital cost plus the power cost. 

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