content
Introduction 1
I How to Use This Book 1
(A) The Case Study Approach 1
(B) A "Road Map" 2
II Some Advice 3
(A) General Advice to the Student 3
(B) Advice from a Former Design Project Student 4
(C) To the Lecturer 5
(D) The Designer or Project Engineer 7
III Presentation of Design Projects 7
(A) Effective Communications 7
(B) General Comments on Preparation of Literature Surveys 9
IV Details of Particular Design Projects, and Information Sources 14
(A) IChemE Design Projects 14
Instructions for the IChemE Design Project, 1980 16
(B) Information Sources 20
PART 1 TECHNICAL AND ECONOMIC FEASIBILITY STUDY
Chapter 1 The Design Problem 27
1.1 Initial Considerations and Specification 27
1.1.1 The Feasibility Study 27
1.1.2 Time Management 28
1.1.3 Stages in a Design Problem 28
1.1.4 The Search for Information 28
1.1.5 Scope of the Project 29
1.1.6 Evaluating the Alternatives - Making Decisions 29
Some Questions to Ask for the Chemical to be Produced 30
Further Reading 30
I How to Use This Book 1
(A) The Case Study Approach 1
(B) A "Road Map" 2
II Some Advice 3
(A) General Advice to the Student 3
(B) Advice from a Former Design Project Student 4
(C) To the Lecturer 5
(D) The Designer or Project Engineer 7
III Presentation of Design Projects 7
(A) Effective Communications 7
(B) General Comments on Preparation of Literature Surveys 9
IV Details of Particular Design Projects, and Information Sources 14
(A) IChemE Design Projects 14
Instructions for the IChemE Design Project, 1980 16
(B) Information Sources 20
PART 1 TECHNICAL AND ECONOMIC FEASIBILITY STUDY
Chapter 1 The Design Problem 27
1.1 Initial Considerations and Specification 27
1.1.1 The Feasibility Study 27
1.1.2 Time Management 28
1.1.3 Stages in a Design Problem 28
1.1.4 The Search for Information 28
1.1.5 Scope of the Project 29
1.1.6 Evaluating the Alternatives - Making Decisions 29
Some Questions to Ask for the Chemical to be Produced 30
Further Reading 30
Case Study: Production of Phthalic Anhydride 31
Overall Summary for the Technical and Economic Feasibility Study 31
1.2 Case Study - Defining the Problem and Background Information 32
Summary 32
1.2.1 Background and Objectives 32
1.2.2 Chemical Structure and Physical Properties 32
1.2.3 Applications and Uses 33
1.2.4 Basic Chemistry 33
1.2.5 Evaluation of Alternative Processing Schemes 34
1.2.6 Conclusions 35
1.2.7 Recommendations 35
Chapter 2 Feasibility Study and Market Survey 37
2.1 Initial Feasibility Study 37
2.2 Preliminary Market Survey/Economic Analysis 37
References 40
2. 3 Information Sources 40
2.4 Evaluation of Available Literature 41
2.5 Considerations for Literature Surveys 42
References 42
2.6 Case Study - Feasibility Study and Market Assessment 43
Summary 43
2.6.1 Market Assessment 43
2.6.1.1 Production: Worldwide 43
2.6.1.2 Production: Regional 44
2.6.1.3 Production: National 44
2.6.2 Current and Future Prices 45
2.6.3 Demand 45
2.6.4 Australian Imports and Exports 46
2.6.5 Plant Capacity 46
2.6.6 Product Value and Operating Costs 47
2.6.6.1 Capital Costs 47
2.6.6.2 Operating Costs 47
2.6.6.3 Approximate Selling Price 47
2.6.7 Conclusions 48
2.6.8 Recommendations 49
Chapter 3 Process Selection, Process Description and Equipment List 51
3.1 Process Selection Considerations 51
3.1.1 Flow Diagrams - PFD and P&ID 51
3.1.2 The Reactor 51
3.1.3 Product Purity 52
3.1.4 Process Conditions 52
Overall Summary for the Technical and Economic Feasibility Study 31
1.2 Case Study - Defining the Problem and Background Information 32
Summary 32
1.2.1 Background and Objectives 32
1.2.2 Chemical Structure and Physical Properties 32
1.2.3 Applications and Uses 33
1.2.4 Basic Chemistry 33
1.2.5 Evaluation of Alternative Processing Schemes 34
1.2.6 Conclusions 35
1.2.7 Recommendations 35
Chapter 2 Feasibility Study and Market Survey 37
2.1 Initial Feasibility Study 37
2.2 Preliminary Market Survey/Economic Analysis 37
References 40
2. 3 Information Sources 40
2.4 Evaluation of Available Literature 41
2.5 Considerations for Literature Surveys 42
References 42
2.6 Case Study - Feasibility Study and Market Assessment 43
Summary 43
2.6.1 Market Assessment 43
2.6.1.1 Production: Worldwide 43
2.6.1.2 Production: Regional 44
2.6.1.3 Production: National 44
2.6.2 Current and Future Prices 45
2.6.3 Demand 45
2.6.4 Australian Imports and Exports 46
2.6.5 Plant Capacity 46
2.6.6 Product Value and Operating Costs 47
2.6.6.1 Capital Costs 47
2.6.6.2 Operating Costs 47
2.6.6.3 Approximate Selling Price 47
2.6.7 Conclusions 48
2.6.8 Recommendations 49
Chapter 3 Process Selection, Process Description and Equipment List 51
3.1 Process Selection Considerations 51
3.1.1 Flow Diagrams - PFD and P&ID 51
3.1.2 The Reactor 51
3.1.3 Product Purity 52
3.1.4 Process Conditions 52
3.1.5 Process Data 52
3.1.6 Energy Efficiency 52
3.1.7 Factors in Process Evaluation and Selection 53
3.1.8 Choices and Compromises 53
3.1.9 The Optimum Design 54
3.1.10 Process Control and Instrumentation 54
References 54
3.2 Process Description 55
3.3 Preparing the Equipment List 55
3.4 Rules of Thumb 56
3.5 Safety Considerations and Preliminary HAZOP Study 57
References 57
3.6 Case Study - Process Selection and Equipment List 58
Summary 58
3.6.1 Trends in Phthalic Anhydride Processing 58
3.6.2 Raw Material 58
3.6.3 Process Configurations 59
3.6.4 Detailed Process Description 61
3.6.5 Advantages of the LAR Process 62
3.6.6 Advantages of the LEVH Process 62
3.6.7 Process Selection 62
3.6.8 Initial Equipment Design 63
3.6.9 Equipment List 63
3.6.10 Conclusions 64
3.6.11 Recommendations 64
Appendix A: Preliminary Equipment Specifications 65
Chapter 4 Site Considerations: Site Selection and Plant Layout 69
4.1 Site Selection/ Location 69
4.1.1 Local Industrial Areas 69
4.1.2 Some Important Factors 70
4.1.3 Prioritizing the Factors 70
References 71
4.2 Plant Layout 71
4.2.1 Plant Layout Strategies 72
4.2.2 Factors Influencing Plant Layout 72
References 73
4.3 Case Study - Site Considerations: Site Selection and Plant Layout 74
Summary 74
4.3.1 Background and Objectives 74
4.3.2 Potential Sites 75
4.3.2.1 Kemerton 76
4.3.2.2 Geraldton 76
3.1.6 Energy Efficiency 52
3.1.7 Factors in Process Evaluation and Selection 53
3.1.8 Choices and Compromises 53
3.1.9 The Optimum Design 54
3.1.10 Process Control and Instrumentation 54
References 54
3.2 Process Description 55
3.3 Preparing the Equipment List 55
3.4 Rules of Thumb 56
3.5 Safety Considerations and Preliminary HAZOP Study 57
References 57
3.6 Case Study - Process Selection and Equipment List 58
Summary 58
3.6.1 Trends in Phthalic Anhydride Processing 58
3.6.2 Raw Material 58
3.6.3 Process Configurations 59
3.6.4 Detailed Process Description 61
3.6.5 Advantages of the LAR Process 62
3.6.6 Advantages of the LEVH Process 62
3.6.7 Process Selection 62
3.6.8 Initial Equipment Design 63
3.6.9 Equipment List 63
3.6.10 Conclusions 64
3.6.11 Recommendations 64
Appendix A: Preliminary Equipment Specifications 65
Chapter 4 Site Considerations: Site Selection and Plant Layout 69
4.1 Site Selection/ Location 69
4.1.1 Local Industrial Areas 69
4.1.2 Some Important Factors 70
4.1.3 Prioritizing the Factors 70
References 71
4.2 Plant Layout 71
4.2.1 Plant Layout Strategies 72
4.2.2 Factors Influencing Plant Layout 72
References 73
4.3 Case Study - Site Considerations: Site Selection and Plant Layout 74
Summary 74
4.3.1 Background and Objectives 74
4.3.2 Potential Sites 75
4.3.2.1 Kemerton 76
4.3.2.2 Geraldton 76
4.3.3 Preferred Site and Layout 76
4.3.4 Conclusions 80
4.3.5 Recommendations 81
Chapter 5 Environmental Considerations 83
5.1 Environmental Impact Assessment 83
5.2 General Considerations 83
5.3 EIA Policy and Scope 85
5.4 EIA Reports 86
5.5 Australia 88
5.6 United Kingdom 88
5.7 United States 89
5.8 ISO-14000 90
5.9 Legislation 90
References 91
5.10 Case Study - Environmental Considerations 92
Summary 92
5.10.1 Purpose 93
5.10.2 Airborne Emissions 93
5.10.3 Waterborne Emissions 95
5.10.4 Solid Waste 95
5.10.5 Process Hazards 96
5.10.6 Accidental Spills and Tank Breaches 96
5.10.7 Personnel Safety Precautions and Procedures 98
5.10.8 Conclusions 98
5.10.9 Recommendations 99
Chapter 6 Economic Evaluation 101
6.1 Introductory Notes 101
6.2 Capital Cost Estimation 102
6.2.1 Cost of Equipment (Major Items) 103
(I) Cost Correlations 103
(II) Factored Estimate Method 104
6.2.2 Module Costs 105
6.2.3 Auxiliary Services 105
6.3 Operating Costs - Fixed and Variable 106
6.3.1 Depreciation 108
6.4 Profitability Analysis 109
6.4.1 The Payback Period 110
6.4.2 Return on Investment (ROI) 110
6.4.3 Evaluating Different Scenarios 110
6.4.4 Economic Evaluation and Analysis 111
4.3.4 Conclusions 80
4.3.5 Recommendations 81
Chapter 5 Environmental Considerations 83
5.1 Environmental Impact Assessment 83
5.2 General Considerations 83
5.3 EIA Policy and Scope 85
5.4 EIA Reports 86
5.5 Australia 88
5.6 United Kingdom 88
5.7 United States 89
5.8 ISO-14000 90
5.9 Legislation 90
References 91
5.10 Case Study - Environmental Considerations 92
Summary 92
5.10.1 Purpose 93
5.10.2 Airborne Emissions 93
5.10.3 Waterborne Emissions 95
5.10.4 Solid Waste 95
5.10.5 Process Hazards 96
5.10.6 Accidental Spills and Tank Breaches 96
5.10.7 Personnel Safety Precautions and Procedures 98
5.10.8 Conclusions 98
5.10.9 Recommendations 99
Chapter 6 Economic Evaluation 101
6.1 Introductory Notes 101
6.2 Capital Cost Estimation 102
6.2.1 Cost of Equipment (Major Items) 103
(I) Cost Correlations 103
(II) Factored Estimate Method 104
6.2.2 Module Costs 105
6.2.3 Auxiliary Services 105
6.3 Operating Costs - Fixed and Variable 106
6.3.1 Depreciation 108
6.4 Profitability Analysis 109
6.4.1 The Payback Period 110
6.4.2 Return on Investment (ROI) 110
6.4.3 Evaluating Different Scenarios 110
6.4.4 Economic Evaluation and Analysis 111