PSE

Introduction to Chemical Plant Design Life Cycle

Process Safety Consideration

PSE

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.

PSE A design project

• Survey/feasibility studies

• Project structure/planning (milestone)

• Design

• Safety, Health & Environment

Desired Products

PROCESS ?

Raw materials?

Process Structure

PSE

Methane

Ammonia

Methanol

Ethylene

Oxide

Chloralkali

Plant

Ethane

Propane

Ammonia

MTBE

Urea

Formadehyde

Ammonia Urea

Ammonium Nitrate

Ammonium Phosphate

Polyvinyl Chloride

Titanium Dioxide

Silicones

Polyethylene LDPE

Glycol

Surfactant

Polypropylene

Acrylics

Acrylonitrile

Caprolactam Terephthalic Acid

Polystyrene

ABS, SAN

MTBE

Unsaturated Esters

Butane

Benzene

End Uses of Fractionated Raw Natural Gas

Middle Distillates

PSE

Naphtha Utilisation For Petrochemicals (1/2)

Cl2

EDC/VCM Polyvinyl Chloride

LDPE Acetic Acid

Vinyl Acetate Polyvinyl Acetate

LLDPE/HDPE

Ethylene O2 H2O

PTA Polyester Polyethylene

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

PSE

Naphtha Utilisation For Petrochemicals (2/2)

O2

(By Products) n - Butane Acetic Acid

Acrylonitrile

Butene - 1

Mixed C 4

Butadiene Polybutadiene (Synthetic Butadiene Rubber)

H2

HMDA Nylon 6,6

Adiponitrile

Nylon 6

Butene - 2 Isobutene Polybutene

MTBE (ABS)

Naphtha

Cracker Toluene Toluene Diisocyanate (TDI) Nylon-6

C2

Benzene Ethylbenzene Styrene Polystyrene

Pyrolysis C3 O2

Gasoline Mix-xylene Phenol Cyclohexanone Caprolactam

Acetic Acid EG

Para - xylene Pure Terephthalic Acid (PTA) Polyester Fiber

Fuel Oil

Fuel Gas

Caprolactam

PSE 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

PSE 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.

PSE 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.

PSE 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.

PSE 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.

PSE

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.

PSE 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 up-

date.

- Poor planning.

- Lack of safety analysis.

- Lack of technical and

reaction knowledge.

- Poor safety culture.

- Poor inspection and

maintenance.

- Poor management of

change.

PSE

Value

Idea Pre-design Basic design Detailed

design Fabrication/Installation Operation R&D

Good project & good

implementation

Good project & poor

implementation

Poor project & good

implementation

Poor project & poor

implementation