Chapter 2(R)

DEFINITION OF A PROCESS PLANT

2.1 Introduction
A plant design project begins with its definition. In its broadest meaning, the
definition states the scope of the project. Without the scope, the project remains
unspecified. This is certainly necessary for assessing the project cost right from the
beginning (9).
A need such as listed below may lead to the start of a plant design project and this is
first expressed through statements like:
a. There will be a need for acetylene and oxygen at KAFCO (Karnaphuli
Fertilizer Co Ltd) plant site during plant erection. (Future)
b. Carbon dioxide removal system using arsenic based absorbent is to be
replaced with a non-toxic system in plants in Bangladesh.
c. Effluents from UFFL are causing pollution of surrounding areas. Present Continuous
d. Chromate removal system at ZFCL does not work. Present Tense

e. Regeneration of ion-exchange beds with hydrochloric acid at NDL will

be cost effective.
These open ended general statements are good examples of primitive problems (2).
These problems simply state the existence of needs and arc ray, defined enough to
initiate a project right away. Such a primitive problem may be stated or raised by any
individual. The characteristic of a primitive problem is its inadequate description for
determining the scope (2).
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
autarky".
Any one of the following stated problems if solved might meet our need of fertilizer to
achieve food autarky.

1
 i Design a processing system to synthesize urea in prill or granular form using
natural gas as feed stock and fuel.
ii Design a processing system based on local naphtha to synthesize urea.
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
digester sludge as fertilizer.

2.2 Specific Problem:

Now the process/design engineer must identify which of these stated alternatives
would best meet the need of nitrogen based fertilizer in Bangladesh. Identifying the
correct problem is a challenging task (2). A rational approach is to prepare a list of
feasible alternatives and the solution of some of them may solve the stated problem
satisfactorily. These different alternatives are now to be examined considering
technological, economic and other connected issues. Finally, we deal with the selected
problem to satisfy the need.

Examples of specific problems are:

a. A 10,000 t/year sulfuric acid plant based on imported sulfur is to be built

at Bogra.
b. A 20,000 t/year ammonium nitrate plant is to be built with locally
produced ammonia at Ashugonj.
c. A 5,000 t/year technical grade ethanol is to be produced by fermenting
available molasses from sugar mills at Rajshahi.

2.2.1 Feasibility Study: Before initiating the detailed design, the need which has
given rise to primitive and specific problem has to be examined on the basis of
technical and economic considerations. A feasibility study or survey consisting of
technical and economic aspects including potential market conditions for the
particular product and raw material will indicate the probable success of the project
and also establish what additional data and information are required to complete the
evaluation. A feasibility studyis to include the following (l, 3, 8):

1. Raw materials ( sources, quantity, quality, cost)

2. Process know-how and alterative production technologies
3. Facilities and equipment available
4. Facilities and equipment to be procured
5. Production costs and total investment
6. Profits and profitability analysis
7. Materials of construction

2
 8. Safety considerations
9. Market (possible and potential, price trend of products and byproducts,
distribution of customers)
10. Competition (overall, specifications of available products, equivalent products)
11. Product specification (chemical and physical specifications, impurities, shelf
life)
12. Sales and sales services
13. Shipping restrictions and containers
14. Plant location
15. Process licensing and related legal matters
16. Environmental impact assessment/statement (EIA/S)

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
comparison of different processes, plant location and process cycle. Considerations for
comparing alternative processes are listed below (l, 3):

1. Technical (process and its provenness, operability, controls, yields,

energy and utility consumptions, hazards, etc.)
2. Raw materials (sources, upgrading and storage requirements)
3. Waste products and byproducts (quantity, value, likely uses, disposal if
required and environmental impacts therefor)
4. Equipment (sources, reliability and provenness, initial costs,
maintenance, proprietary designs, job standards, etc.)
5. Costs (raw materials, utilities, depreciation and other fixed charges,
royalty payment, effluent treatment, etc.)
6. Time requirement (project implementation, completion of process
development and design, etc.)
7. Process considerations (technology, provenness, scale-up, alternative
uses of raw materials, etc.)
8. Plant location
Considering the relevance of environmental aspects for today's process plant, a
feasibility study should provide information in reference to environmental impact
statement (EIS) which is often a requirement. (Government regulations).

For many projects, prefeasibility studies are undertaken at the inception stage prior to
feasibility studies. A prefeasibility study usually covers:

Market survey, process technology and economic viability

It is a recognized practice in process industries to apply continuous process wherever

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

3
better performed batch wise while the remaining process is carried out on a
continuous basis by incorporating sufficient intermediate storages between operations
(3). Examples arc: Fermentation Process, Pulp Production, etc.

2.2.2 Plant Site Selection: Location of a plant can be a decisive factor in determining
the economic success of a process plant. The factors which usually influence the
selection of a plant site include (l, 3, 4, 5, 6, 7):

raw materials, markets, utilities availability, climate, transport

facilities, water supply, waste disposal, labour supply, site
characteristics, flood and fire protection, community factors,
taxation, legal requirements and environmental considerations

In Bangladesh, political considerations in some cases have over shadowed real

considerations for selecting sites for plants, Examples are: CUFL, Kuliarchar
Ground Nut Oil Mills, etc.

While undertaking the feasibility study, plant site characteristics, climatic data
and product shipment methods and safety requirements arc to be presented in-
depth to have the project well defined. These aspects are dealt at length in
standard text books.
In many countries including Bangladesh, for the plant site and project
implementation, certain permissions and authorization from the Government,
local authorities and departments are to be obtained. These are required in respect
of the following in forms such as:
- rights of way (r. o. w) for crossing of roads, railroads, rivers, canals, bridges,
etc. for pipelines transporting water, gas, oil, etc.
- lease (acquisition) of lands for pipelines, power lines, sewer lines, etc.
- permission by the Railway Department to construct railroad and its tie-lit) with
existing systems
- permission from Inland Water Transport Authority to use water ways
- approval by Port Authority or Inland Water Transport Authority for
constructing jetty
- approval by Civil Aviation Department for constructing tall structures close to
the airport and painting requirements for the structure
- approval from relevant authorities for dredging the river for site filling or
changing the landscape by felling forests or cutting of the hills, etc.
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
as needed.

4
Local environmental laws and requirements are to be met in terms of the limits set for
discharges to water streams or air from the plants. These requirements are revised
regularly and new revisions ask for better control of pollutants trough installation of
treatment facilities.
2.3 Defined Problem
Let us now take an example of certain defined project:
“A fertilizer plant is to be set-up at Sirajgonj in Bangladcsh having a capacity of
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,
corresponding to 330,000 t of ammonia per year, including all off sites, auxiliaries,
utilities and supporting facilities using natural gas as feedstock and fuel”.
The defined project states the scope of the project in a broad sense and the design
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
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
referred to as-Technical Specification (See Chapter 3R for details)which is used as a
guideline for developing engineering and design for the project. This is a separate
document which is distinctly identifiable with the project.
As already mentioned the defined project states the scope of the project in general
terms. However, for the purpose of preparation of enquiry documents for the selection
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
as well as the client's responsibilities for the project. Table I lists the details of the
scope of work and supply of a turnkey type job.
Work means all activities related to engineering and services while supplies include
equipment, materials, etc. for the plant. This table is indicative in nature to emphasize
its relevance to the project from execution view point. It is worthwhile to make a table
containing the scope of the work itemwise along with the responsible parties. This
table will also help in identifying items which have been missed but needed for the
execution of the project. It is worth emphasizing here that the scope of the project is
required by both the client and the contractor for making an estimate too. In absence
of a well-conceived scope, the project may end up as a financial disaster due to cost
overruns and any engineering manager whether he works for the client or for the
engineering contractor must be aware of it.

5
 TABLE 2.1: SCOPE OF WORK AND SUPPLY FOR A TURNKEY TYPE
PROJECT
Scope of Contractor's Work
(1) Engineering
1. Process Engineering (including process licensing arrangement if needed)
2. Mechanical Engineering for all Equipment including Metallurgy
3. Plant and Piping Engineering
4. Instrumentation
5. Electrical
6. Civil
7. Architecture
(2) Procurement of the equipment, materials and all types of engineering services.
Such as erection, construction, start-up and commissioning, etc. for the plant
(3) Transportation with respect to equipment and materials procured and
responsibilities include:
1. Arrangement for shipping
2. Actual shipment
3. Inland transportation from the pons in the country to the plant site
4. Customs clearance
5. Transportation of materials procured locally

(4) Training of the client's personnel

(5) Supply of Technical Documents (A list is to be prepared at the early stage of
work, preferably at time of signing the contract)
(6) Site Receiving, Handling and warehousing which include:
(a) Unloading at the site
(b) Storing
(c) Receiving and issuing of equipment and materials

(7) Temporary Works (needed by the contractor)

These include:

1. Temporary warehouse
2. Temporary office plus telephone, telex, fax, etc.
3. Temporary workshop
4. Water supply within the site
5. Electricity supply within the site
6. Temporary sewer and drainage system
7. Temporary firefighting equipment
8. Furniture for temporary facilities
9. Temporary site canteen

6
 10. Camp accommodation for contractor's and its subcontractor's personnel
11. Other temporary facilities within the site as required such as scaffolding, fencing, guard house, etc.
The temporary facilities constructed by the contractor are cleared away by the
contractor upon completion of the erection work, or on the set time schedule.

(8) Construction work.

1. Civil Work (piling, foundation, structure, roads drains, pavements, etc.)

2. Installation Work
3. Piping Work
4. Electrical Work (e) Instrumentation Work
5. Insulation Work
6. Painting Work
7. Safety and Security Work Field Inspection Work
8. Flushing and Chemical Cleaning
9. Mechanical Completion of the Equipment and Units

(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. Steel Structures and Pipe Racks’
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).

7
 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).
8. Leibson, I. and C. A. Trischman, Jr., A Realistic Project Dcvelopmcnt Case
study, Chem. Eng. 78 (20), 86 (1971).
9. Baascl, W. D. , Preliminary Chemical Engineering Plant Design, Elsevier Pub.
co., New York (1976).