Chapter 2(R) iii Design a processing system to produce urea based on imported ammonia from

the Middle East using carbon dioxide from flue gases of thermal power
stations.
iv Design bio-gas generation systems using agriculture residue and apply the
DEFINITION OF A PROCESS PLANT
digester sludge as fertilizer.

2.2 Specific Problem

2.1 Inception
A plant design project begins with its definition. In its broadest meaning, the Now the process/design engineer must identify which of these stated alternatives
definition states the scope of the project. Without the scope, the project remains would best meet the need of nitrogen based fertilizer in Bangladesh. Identifying the
unspecified. This is certainly necessary for assessing the project cost right from the correct problem is a challenging task (2). A rational approach is to prepare a list of
beginning (9). feasible alternatives and the solution of some of them may solve the stated problem
satisfactorily. These different alternatives are now to be examined considering
A need such as listed below may lead to the start of a plant design project and this is technological, economic and other connected issues. Finally, we deal with the selected
first expressed through statements like: problem to satisfy the need.
a. There will be a need for acetylene and oxygen at KAFCO (Karnaphuli
Fertilizer Co Ltd) plant site during plant erection. Examples of specific problems are:

b. Carbon dioxide removal system using arsenic based absorbent is to be a. A 10,000 t/year sulfuric acid plant based on imported sulfur is to be built
replaced with a non-toxic system in plants in Bangladesh. at Bogra.
b. A 20,000 t/year ammonium nitrate plant is to be built with locally
c. Effluents from UFFL are causing pollution of surrounding areas.
produced ammonia at Ashugonj.
d. Chromate removal system at ZFCL does not work. c. A 5,000 t/year technical grade ethanol is to be produced by fermenting
available molasses from sugar mills at Rajshahi.
e. Regeneration of ion-exchange beds with hydrochloric acid at NDL will
be cost effective.
2.2.1 Feasibility Study: Before initiating the detailed design, the need which has
These open ended general statements are good examples of primitive problems (2). given rise to primitive and specific problem has to be examined on the basis of
These problems simply state the existence of needs and arc ray, defined enough to technical and economic considerations. A feasibility study or survey consisting of
initiate a project right away. Such a primitive problem may be stated or raised by any technical and economic aspects including potential market conditions for the
individual. The characteristic of a primitive problem is its inadequate description for particular product and raw material will indicate the probable success of the project
determining the scope (2). and also establish what additional data and information are required to complete the
evaluation. A feasibility study includes the following (l, 3, 8):
Let us look at one such down to earth primitive problem:
"There will be a need for more nitrogen based fertilizer in Bangladesh to achieve food 1. Raw materials ( sources, quantity, quality, cost)
autarky". 2. Process know-how and alterative production technologies
3. Facilities and equipment available
Any one of the following stated problems if solved might meet our need of fertilizer to
4. Facilities and equipment to be procured
achieve food autarky.
5. Production costs and total investment
i Design a processing system to synthesize urea in prill or granular form using 6. Profits and profitability analysis
natural gas as feed stock and fuel. 7. Materials of construction
ii Design a processing system based on local naphtha to synthesize urea. 8. Safety considerations
9. Market (possible and potential, price trend of products and byproducts,
distribution of customers)

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 10. Competition (overall, specifications of available products, equivalent products)
11. Product specification (chemical and physical specifications, impurities, shelf 2.2.2 Plant Site Selection: Location of a plant can be a decisive factor in determining
life) the economic success of a process plant. The factors which usually influence the
12. Sales and sales services selection of a plant site include (l, 3, 4, 5, 6, 7):
13. Shipping restrictions and containers
14. Plant location
raw materials, markets, utilities availability, climate, transport
15. Process licensing and related legal matters
facilities, water supply, waste disposal, labour supply, site
16. Environmental impact assessment/statement (EIA/S)
characteristics, flood and fire protection, community factors,
taxation, legal requirements and environmental considerations
Items 9 through 13 are to be considered for a complete market analysis. While
undertaking the feasibility study, it is essential that a detailed study is made on
In Bangladesh, political considerations in some cases have over shadowed real
comparison of different processes, plant location and process cycle. Considerations for
considerations for selecting sites for plants, Examples are: CUFL, Kuliarchar
comparing alternative processes are listed below (l, 3):
Ground Nut Oil Mills, etc.
1. Technical (process and its provenness, operability, controls, yields,
While undertaking the feasibility study, plant site characteristics, climatic data
energy and utility consumptions, hazards, etc.)
and product shipment methods and safety requirements arc to be presented in-
2. Raw materials (sources, upgrading and storage requirements)
depth to have the project well defined. These aspects are dealt at length in
3. Waste products and byproducts (quantity, value, likely uses, disposal if
standard text books.
required and environmental impacts therefor)
4. Equipment (sources, reliability and provenness, initial costs, In many countries including Bangladesh, for the plant site and project
maintenance, proprietary designs, job standards, etc.) implementation, certain permissions and authorization from the Government,
5. Costs (raw materials, utilities, depreciation and other fixed charges, local authorities and departments are to be obtained. These are required in respect
royalty payment, effluent treatment, etc.) of the following:
6. Time requirement (project implementation, completion of process
rights of way (r. o. w) for crossing of roads, railroads, rivers, canals,
development and design, etc.)
bridges, etc. for pipelines transporting water, gas, oil, etc.
7. Process considerations (technology, provenness, scale-up, alternative
lease (acquisition) of lands for pipelines, power lines, sewer lines, etc.
uses of raw materials, etc.) permission by the Railway Department to construct railroad and its tie-lit) with
8. Plant location existing systems
Considering the relevance of environmental aspects for today's process plant, a permission from Inland Water Transport Authority to use water ways
feasibility study should provide information in reference to environmental impact approval by Port Authority or Inland Water Transport Authority for
statement (EIS) which is often a requirement. (Government regulations). constructing jetty
approval by Civil Aviation Department for constructing tall structures close to
For many projects, prefeasibility studies are undertaken at the inception stage prior to the airport and painting requirements for the structure
feasibility studies. A prefeasibility study usually covers: approval from relevant authorities for dredging the river for site filling or
changing the landscape by felling forests or cutting of the hills, etc.
Market survey, process technology and economic viability Before the work begins, all permits and authorization must be obtained from the
authorized departments and bodies, plus compensation if any to be made must be paid
It is a recognized practice in process industries to apply continuous process wherever as needed.
feasible for its several advantages over the batch process. Batch processing is also
used in processing industries. Sometimes, a number of operations in a process can be Local environmental laws and requirements are to be met in terms of the limits set for
better performed batch wise while the remaining process is carried out on a discharges to water streams or air from the plants. These requirements are revised
continuous basis by incorporating sufficient intermediate storages between operations regularly and new revisions ask for better control of pollutants trough installation of
(3). Examples are: Fermentation Process, Pulp Production, etc. treatment facilities.

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2.3 Defined Problem 7. Architecture
(2) Procurement of the equipment, materials and all types of engineering services.
Let us now elaborate on a certain defined project:
Such as erection, construction, start-up and commissioning, etc. for the plant
-up at Sirajgonj in Bangladcsh having a capacity of
(3) Transportation with respect to equipment and materials procured and
1,700 t of prilled urea per stream day, corresponding to 561,000 t of prilled urea per
year, and an intermediate capacity of 1,000 t of ammonia per stream day, responsibilities include:
corresponding to 330,000 t of ammonia per year, including all off sites, auxiliaries, 1. Arrangement for shipping
utilities and suppo 2. Actual shipment
3. Inland transportation from the pons in the country to the plant site
The defined project states the scope of the project in a broad sense and the design 4. Customs clearance
5. Transportation of materials procured locally
team can now initiate its work for realizing the goal of the project. Once the team
begins its work on the project, it will be obvious that there are many things which are
(4) Training of the client's personnel
not yet defined or established to complete the engineering and planning of the project.
The project in terms of an engineering problem is defined in a form, commonly (5) Supply of Technical Documents (A list is to be prepared at the early stage of
referred to as-Technical Specification (See Chapter 3R for details) which is used as a work, preferably at time of signing the contract)
guideline for developing engineering and design for the project. This is a separate
document which is distinctly identifiable with the project. (6) Site Receiving, Handling and warehousing which include:
1. Unloading at the site
As already mentioned the defined project states the scope of the project in general 2. Storing
terms. However, for the purpose of preparation of enquiry documents for the selection 3. Receiving and issuing of equipment and materials
of an engineering contractor, one requires a clear statement about the scope of work.
This will help in identifying the parties responsible for each item of the scope of work (7) Temporary Works (needed by the contractor) which include:
as well as the client's responsibilities for the project. Table 2.I lists the details of the
scope of work and supply of a turnkey type job. 1. Temporary warehouse
2. Temporary office plus telephone, telex, fax, etc.
Work means all activities related to engineering and services while supplies include 3. Temporary workshop
equipment, materials, etc. for the plant. It is worthwhile to make a table containing the 4. Water supply within the site
scope of the work itemwise along with the responsible parties. Table 2.1 will help in 5. Electricity supply within the site
identifying items which are needed for the successful execution of the project. It is 6. Temporary sewer and drainage system
worth emphasizing here that the scope of the project is required to be clearly 7. Temporary firefighting equipment
understood by both the client and the contractor for making an estimate as well. In 8. Furniture for temporary facilities
absence of a well-conceived scope, the project may end up as a financial disaster due 9. Temporary site canteen
to cost overruns and any engineering manager whether he works for the client or for 10. Camp accommodation for contractor's and its subcontractor's personnel
the engineering contractor must be aware of it. 11. Other temporary facilities within the site as required such as scaffolding, fencing, guard
house, etc.
TABLE 2.1: SCOPE OF WORK AND SUPPLY FOR A TURNKEY TYPE The temporary facilities constructed by the contractor are cleared away by the
PROJECT
contractor upon completion of the erection work, or on the set time schedule.
Scope of Contractor's Work
(1) Engineering (8) Construction work.
1. Process Engineering (including process licensing arrangement if needed)
2. Mechanical Engineering for all Equipment including Metallurgy 1. Civil Work (piling, foundation, structure, roads drains, pavements, etc.)
3. Plant and Piping Engineering 2. Installation Work
4. Instrumentation 3. Piping Work
5. Electrical 4. Electrical Work (e) Instrumentation Work
6. Civil 5. Insulation Work

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 6. Painting Work 8. Leibson, I. and C. A. Trischman, Jr., A Realistic Project Dcvelopmcnt Case
7. Safety and Security Work Field Inspection Work study, Chem. Eng. 78 (20), 86 (1971).
8. Flushing and Chemical Cleaning
9. Baascl, W. D. , Preliminary Chemical Engineering Plant Design, Elsevier Pub.
9. Mechanical Completion of the Equipment and Units
co., New York (1976).
(9) Commissioning
(10) Performance Tests
Scope of the Contractor's Supply
1. All Itemized Equipment
2. Piping Materials Including Accessories
3. Instrument Equipment and Materials
4. Electrical Equipment and Materials
5.
6. Insulation and Painting Materials
7. Bulk Materials (Pipes, fittings, valves, traps, etc.)
8. Spare Parts as Agreed plus any other things

The Client's Scope of Work

1. Process Licensing (if needed)
2. Review and Approval of all Engineering Documents Produced by the Contractor
3. Obtaining Permits and Import License
4. Assistance to Contractor for Customs Clearance
5. Test Operation and Performance under the Direction and Supervision of the Contractor

The Client's Scope of Supply

1. Handing Over the Plant Site to the Contractor in Conditions as Agreed
2. Equipment and Materials Itemized
3. Raw materials, Utilities, etc. Itemized
4. Bond Area for Speedy Delivery of the Equipment and Materials from the Port after Arrival.

References
1. Peters, M. S. and K. D. Timmerhaus, Plant Design and Economics for
Chemical Engineers, 3rd edn., McGraw-Hill Book Co., New York (1981).
2. Rudd, D. F, and C. C. Watson, Strategy of Process Engineering, John Wiley
and Sons New York (1968).
3. Vilbrandt, F. C. and C. E. Dryden, Chemical engineering Plant Design,
McGraw-Hill Book co., New York (1959).
4. Ludwig, E. E., Applied Process Design for Chemical and Petrochemical Plants,
Vol. l, 2nd Cdn. Gulf Pub. Co., Houston (1977).
5. Mears, R. B., Plant Site Layout Minimize Corrosion, Chem. Eng., Jan. I l , 144
(1960).
6. Yocom, J. E, G. F. Collins, and N. E. Bowne, Plant Site Selection, Chem. Eng.,
78 (14), 164 (1971).
7. Martin, R., How to Get Site Sclcction Data, Petro/Chem. Eng., 39(4), 40
(1967).

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