Introduction to Chemical Plant Design Life Cycle Process Safety Consideration
Chemical Plant Design A project/endeavour/task to determine the structure of a process to produce a product in the way that is economical, safe, and environmentally friendly.
A design project PROCESS? Raw materials? Survey/feasibility studies Project structure/planning (milestone) Design Process Structure Safety, Health & Environment Desired Products
Middle Distillates MTBE PSE Methanol Urea Methane Formadehyde Ammonia Urea Ammonia Ammonium Nitrate Ammonium Phosphate Polyvinyl Chloride End Uses of Fractionated Raw Natural Gas Ethane Chloralkali Plant Ethylene Oxide Titanium Dioxide Silicones Polyethylene LDPE Glycol Surfactant Polypropylene Propane Ammonia Acrylics Acrylonitrile Caprolactam Terephthalic Acid Polystyrene Benzene Unsaturated Esters Butane ABS, SAN MTBE
Naphtha Utilisation For Petrochemicals (1/2) Cl2 EDC/VCM Polyvinyl Chloride LDPE Acetic Acid Vinyl Acetate Polyvinyl Acetate LLDPE/HDPE Ethylene O2 H2 PTA Polyester Polyethylene O Ethylene Oxide Ethylene Glycol Chips Terephthalate Benzene (PET) Ethylbenzene Styrene Polystyrene Naphtha H2O O2 Cracker Ethyl Alcohol Ethyl Aldehyde Acetic Acid Polypropylene H2O O2 HCN Propylene Isopropanol Acetone Methyl Methacrylate Polymethylmethacrylate Benzene Isopropylbenz O2 Cumene Hydroperoxide Cleavage Phenol / (Cumene) (CHP) Acetone
Naphtha Utilisation For Petrochemicals (2/2) PSE O2 (By Products) n - Butane Acetic Acid Acrylonitrile Butene - 1 Mixed C 4 Butadiene Polybutadiene (Synthetic Butadiene Rubber) Adiponitrile H2 HMDA Nylon 6,6 Caprolactam Nylon 6 Butene - 2 Isobutene Polybutene Naphtha Cracker Toluene Toluene Diisocyanate (TDI) Nylon-6 MTBE (ABS) C2 Benzene Ethylbenzene Styrene Polystyrene Pyrolysis C3 O2 Gasoline Mix-xylene Phenol Cyclohexanone Caprolactam Fuel Oil Acetic Acid EG Para - xylene Pure Terephthalic Acid (PTA) Polyester Fiber Fuel Gas
Plant Design Phases 1. Research 2. Process Development 3. Preliminary Engineering 4. Basic Engineering 5. Detailed Engineering 6. Fabrication, Construction & Installation 7. Start-up 8. Operation
Process Development Target Main tasks and decisions Main safety issues Development of process concept and scale-up to industrial scale. - Idea generation and process creation/innovation. - Laboratory and simulation studies on reaction mechanism and kinetics. - Examination of raw materials (pure and industrial grade). - Laboratory & reaction calorimeter tests. - Process alternatives generation - Bench and pilot scale tests. - Market survey. - Legal and patent check. - Use of hazardous material as feedstock. - Fail to choose the safer state of feedstock. - Incorrect data on the reaction kinetic and reaction behavior. - Incorrect data on runaway reaction potential. - Overlook the chemical reactivity and incompatibility. - Underestimate the effect of impurity, by-product and contaminants. - Unclear mechanism to control the unwanted/runaway reaction. - Inaccurate scale-up.
Preliminary Engineering Target Main tasks and decisions Main safety issues Preliminary process design for the feasibility study. - Process concept selection and flow sheet development. - Selection of unit operations. - Preliminary sizing of equipment. - Preliminary selection of construction material. - Site selection. - Final feed/product specifications. - Feasibility study. - Complicated and extreme routes selection (high temperature and pressure). - Unsuitable types of unit operations. - Unsafe operating conditions. - Overlook the chemical reactivity and incompatibility at process equipment level. - Lack of safety analysis on the chemical contaminations.
Basic Engineering Target Main tasks and decisions Main safety issues Creation of the process data for detailed engineering. - Detailed process design and optimization. - Process design of equipment and piping system. - Basic automation and instrumentation engineering. - Preliminary layout design. - Utilities design. - Waste minimization. - Hazard and operability study. - Inappropriate layout, positioning and physical arrangement. - Incompatible heat transfer medium. - Incorrect heating/cooling sizing. - Inadequate safety and process protection. - Wrong or inaccurate process data for equipment - Unsuitable material of construction. - Failing to consider corrosive environment. - Inappropriate mechanical/ physical and chemical resistance specification. - Incorrect material flow set-up. - Lack of safety analysis.
Detailed Engineering Target Main tasks and decisions Main safety issues Design of the physical process (equipment, piping etc.) for acquisitions and construction. - Detailed piping design. - Detailed layout design. - Instrumentation and automation design. - Mechanical design of the equipment. - Structural and civil engineering. - Electrical design. - Design of utilities/services. - Inappropriate piping layout and protection. - Inappropriate internal shape of equipment/component. - Incorrect location and positioning of support/ attachment/ venting of process equipment. - Inadequate electrical, mechanical and structural/ foundation specification. - Inadequate static, lightning and ignition sources control. - Inadequate detection, automation and instrumentation. - Inadequate operating, start-up, shutdown and emergency manuals. - Wrong specification of buy item. - No back up for utilities failure.
Fabrication, Construction & Installation Target Main tasks and decisions Main safety issues Acquisitions, construction and installation of the process. Starting up the process and make it to meet the specification. - Contracting and bidding. - Contractor selection. - Procurement. - Installation. - Inspection. - Testing. - Field changes. - Part or components miss-match. - Wrong installation or poor work quality. - Incorrect positioning of sensor/ instruments. - Accessibility. - Lack of monitoring and supervision of contractor. - Miscommunication between designer, contractors and plant owner.
Operation Target Main tasks and decisions Main safety issues Safe operations within design specifications and capacity. Improvement of the process. - Selection of safe operation and maintenance principles. - Gathering experience. - Process optimization. - Process improvement - Record keeping on plant histories and technological update. - Poor planning. - Lack of safety analysis. - Lack of technical and reaction knowledge. - Poor safety culture. - Poor inspection and maintenance. - Poor management of change.
Value Good project & good implementation Good project & poor implementation Poor project & good implementation Poor project & poor implementation Idea R&D Pre-design Basic design Detailed design Fabrication/Installation Operation