Chapter Six 6.0 Site and Location and Plant Layout: (Maria, 2003)
Chapter Six 6.0 Site and Location and Plant Layout: (Maria, 2003)
Chapter Six 6.0 Site and Location and Plant Layout: (Maria, 2003)
A suitable site for the alum plant would depend on several factors namely; proximity to the
required feed stock supply, environmental impact of the plant, proximity to the required market
for distribution and operators for handling etc. However, the environmental consideration is by far
the most important factor that must be considered in locating a suitable site.
According to government regulation (Maria, 2003), Alum plants are considered as commercial
plants and ought to be located in industrial zones. However, the location of such plants outside an
industrial area is legal since it does not conflict with public interest, its effluent are biodegradable
The decision to build the plant is made based on a feasibility study. The market for products, the
supply of raw materials, the infrastructural and the recruitment of qualified operators are taken into
consideration. The final result is a cost-benefit calculation based on assumed values (Maria, 2003).
Basically, the economic construction and efficient operation of the process units will depend on
how well the plant and equipment specified on the process flow diagram were laid out. The
Process requirements
Safety
Future expansion
Modular construction
6.1.1 Cost
The cost of construction can be minimized by adopting a layout that gives the shortest run of
connecting pipes between equipment and the least amount of structural steel work. However, this
will not necessarily be the best arrangement for operation and maintenance.
Certain process consideration maybe needed, like the elevation of the base of columns, reactor,
tanks to provide the necessary net positive suction head to a pump or the operating head for a
thermosyphon reboiler.
Equipment that needs operators frequent attention should be located conveniently for easy access
like the valves, sample points. Hence, they should be located at suitable position and height
sufficient working space and head room must be provided to allow easy access to equipment.
Heat exchangers should be suitably sited, so that the tube bundles can be easily withdrawn for
cleaning and tube replacement. Equipment that requires dismantling for maintenance such as
compressors, pumps and motors, should be place under cover. Equipment that requires frequent
cleaning or replacement like the decanter or the filter should be properly located with enough
6.1.5 Safety
Blast walls maybe needed to isolate potentially hazardous equipment and confine the effect of an
explosion. At least two escape routes for operators must be provided from each level in the process
platform.
6.1.6 Future Expansion
Equipment should be located so that it can be conveniently tied in with any future expansion of
the process. Space should be left on pipe alleys for future needs, and sensitive pipes oversized
The modules will include equipment, structural steel, pipe and instrumentation. The advantages of
modular construction or improved quality control, reduced construction cost and lower risk or
hazard potential. While some disadvantages include higher design costs and more slanged
connections.
As easily seen in the process flow diagram, the optimal plant layout of minimal area consumption
based on the triglyceride technique of stearic acid production suggest two reactors in series and
feedstock vessels arranged closely for easy introduction into the reactors and ease in operations.
Table 6.1 shows the surface area occupied by each main unit of the process plant in the production