Process Plant Design Research Articles

Applying graph matching techniques to enhance reuse of plant design information

This article investigates how graph matching can be applied to process plant design data in order to support the reuse of previous designs. A literature review of existing graph matching algorithms is performed, and a group of algorithms is chosen for further testing. A use case from early phase plant design is presented. A methodology for addressing the use case is proposed, including graph simplification algorithms and node similarity measures, so that existing graph matching algorithms can be applied in the process plant domain. The proposed methodology is evaluated empirically on an industrial case consisting of design data from several pulp and paper plants.

PO563 Patients Experiences In Kenya In Quitting Tobacco Use

All process piping projects utilize Computer Aided Design (CAD) in one form or another and to a greater or larger extent. This chapter speaks about the variety of CAD software choices, their functions and the process of selection, and their application in the plant design process. While in essence all CAD software provides one primary function, that of task automation, choices are made between the various vendors’ offerings based on many factors. These factors include, but are not limited to client preference, size of project, cost, and the importance placed on particular functionalities such as the linking of data. In themselves, though no one CAD system is any more capable than another in producing a successful project. It is an understanding of the systems, which in turn facilitates the decisions on appropriate workflows, training requirements, and minimum prerequisites of user experience/capabilities, that make the difference. Consequently, a thorough knowledge of CAD systems must be possessed by the piping lead in order to do their part in the development and implementation of piping-specific CAD processes.

VR System development for nuclear power plant in Korea

By using Virtual Reality(VR) technology which is one of the core technologies 4th industry revolution, we are developing VR System development for Nuclear power plants from April 2018 to March 2021. This Research and Development (R&D) project includes VR based “Walk-down System development”, “optimal path tracking system development”, “major equipment transfer and installation simulation”, etc. When fully developed, These R&D results will be applied the construction of the Shin-Kori unit 5,6 nuclear power plant construction to check design interference, to establish work planning, and to effectively collect construction experience knowledges to improve our future construction projects in the future. This paper will introduce major technological developments contents of this R&D project. It is expected that the results of this study will contribute dramatically to enhance the efficiency of nuclear power plant design process and the method of construction by simulating installation method of major equipment such as reactor, steam generators and turbine before installing them in the Shin-Kori unit 5,6.

VR System development for nuclear power plant in Korea

By using Virtual Reality(VR) technology which is one of the core technologies 4th industry revolution, we are developing VR System development for Nuclear power plants from April 2018 to March 2021. This Research and Development (R&D) project includes VR based “Walk-down System development”, “optimal path tracking system development”, “major equipment transfer and installation simulation”, etc. When fully developed, These R&D results will be applied the construction of the Shin-Kori unit 5,6 nuclear power plant construction to check design interference, to establish work planning, and to effectively collect construction experience knowledges to improve our future construction projects in the future. This paper will introduce major technological developments contents of this R&D project. It is expected that the results of this study will contribute dramatically to enhance the efficiency of nuclear power plant design process and the method of construction by simulating installation method of major equipment such as reactor, steam generators and turbine before installing them in the Shin-Kori unit 5,6.

Optimization-Based Approach for Process Plant Layout

This paper presents an optimization-based approach for the multifloor process plant layout problem. The multifloor process plant layout problem involves determining the most efficient—based on predefined criteria—spatial arrangement of a set of process plant equipment with associated connectivity. A number of cost and management/engineering drivers (e.g., connectivity, operations, land area, safety, construction, retrofit, maintenance, production organization) have been considered over the last two decades in order to achieve potential savings in the overall plant design process. This work constitutes an extension of the work by Patsiatzis and Papageorgiou [ Ind. Eng. Chem. Res. 2003, 42, 811−824;10.1021/ie020586t] to address the multifloor process plant layout problem. New features introduced modeled tall equipment with height greater than the typical floor height in chemical process plants, with connection points at a design-specified height for each piece of equipment. The number of floors, land area, ...

Corrigendum: Detailed design and optimization of a sustainable micro-algal biofuel process plant

Corrigendum: Detailed design and optimization of a sustainable micro-algal biofuel process plant

Process Hazard Analysis of Gasification Process by using Oil Palm Empty Fruit Bunch as Feedstock

Production of hydrogen rich gas from the gasification of biomass to replace fossil fuels has become a common interest worldwide. One of the potential biomass in Malaysia to produce hydrogen rich gas is empty fruit bunch (EFB) from oil palm (Elaeis guineensis). Numerous researchers have carried out studies on hydrogen production using biomass but there are limited researches on the hazards analysis incorporated in the gasification process of EFB. This paper presents the hazards identification and risk reduction of the gasification process by using EFB as a feedstock. The research aims to incorporate safety needs to the gasification process of EFB for safe operation in the future. The process hazards analysis has been carried out on process unit namely fire burner, feeding hopper, fluidised bed reactor and cyclone. The potential hazard, possible causes, risk and consequences of the process unit were analysed. Based on the analysis, the major hazards identified in the process are overpressure and over temperature followed by the release of hydrogen gases. Safe by design is the most effective risk reduction strategy since it can eliminate the hazards from the source by having inherently safer design of the hydrogen process plant.

Detailed design and optimization of a sustainable micro-algal biofuel process plant

A sustainable micro-algal biofuel process plant was hypothetically and detailed-designed for the production of value products from algae. The process plant cultures algae through controlled growth and processes: production of biomass, extraction of lipids and biofuels and refinement into finished products. The start-off feedstock was Nannochloropsis spp. and the four end products produced were bio-kerosene, methane, biomass slurry and CO₂. The algae were grown to maturity within the least allowable possible time under controlled conditions. From an in-depth analysis of the customer specifications, concept development and selection, the study defines an overall depiction of the end products from the concepts evaluated by using the Pugh matrix and Six sigma methodologies. DMADV approach was implemented.The process finally generated an economically viable algae biomass for conversion to biofuels and other viable products. This paper focuses on the process planning, criteria/concept selection, design optimization with necessary characterizations which were filtered into measurable characteristics for the design of an operable, sustainable functioning plant.

A Methodology to Support Manufacturing System Design Using Digital Models and Simulations: An Automotive Supplier Case Study

Emerging tools for digital manufacturing support the decision making during the design of production systems. Simulations have proved to enhance the plant design process by generating accurate predictions allowing the evaluation of different alternatives. However, the use of these tools needs to be guided to achieve an efficient decision-making process. Therefore, this paper proposes a methodology to guide the engineering efforts towards plant design and operation using discrete event simulation tools. The methodology integrates all essential activities to develop, optimize, and validate the plant. The presented methodology aims at specifying the approach taken to generate the technology viewpoint from the Sensing, Smart and Sustainable Enterprise Reference Model (S3E-RM) which allows the integrated manufacturing enterprise design. A case study is presented to demonstrate the results obtained when using the methodology. The case study is a plant from a Tier One Automotive Supplier that produces plastic and metal parts. The advantages and limitations of the proposed methodology are visualized in the case study implementation and then discussed in the conclusions.

Optimal configuration of multiple-chiller plants under cooling load uncertainty for different climate effects and building types

Configuring the number and size of chillers in a multiple-chiller plant properly is an efficient way to improve the plant energy efficiency. At the design stage, the optimal configuration can be achieved through matching the capacity to load as closely as possible across the full-load profile. However, in spite of the fact that current literature offers practical recommendations, a systematic method to optimize the configuration of multiple-chiller plants is lacking. Due to the lack of accurate information at the design stage and only limited knowledge of the eventual realization it is hard to predict the building’s cooling load. Moreover, there is no operational data to predict the system performance. Both explain the existence of uncertainty in the HVAC plant design process. This paper, therefore, proposes a strategy to optimize the configuration of multiple-chiller plants, which takes account of the load side uncertainty as well as the COP uncertainty and selects the optimal configuration through a life-cycle analysis. Both the load side uncertainty and the COP uncertainty are quantified using statistical distributions. To facilitate applications, the distributions of the cooling load profile of different types of buildings under different weather conditions are investigated and are classified into four categories, and the optimal configuration schemes under each type of cooling load distribution are analyzed and summarized in a tabulated form.

Development and performance evaluation of an effective dryer for poundo yam flour processing plant

AbstractThe process of making pounded yam, from yam, Dioscorea spp., which is mostly consumed by people of sub-Sahara region as source of carbohydrate is energy consuming, therefore, the pounded yam flour, commonly called poundo yam, through which pounded yam is prepared faster and easier, has become popular in West Africa. Although there is an existing niche market for the design and production of poundo yam processing plant, proper drying, one of the most important stages in the production line of poundo yam flour is drying to remove moisture from parboiled (a stage before drying) yam chips still remains the limitation to an effective application of the processing plant in the food industry. The development and performance evaluation of an effective drier that will allow the movement of the dried yam chips to the next machine in poundo yam process plant and its suitability to the food industrial applications was carried out in this research. The volume of the drying drum was estimated to be 0.03 m3. The...

Assessing inherent environmental, health and safety hazards in chemical process route selection

During early stages of plant design and development chemical process route selection needs to be carried out considering factors such as inherent safety, health and environment associated with the plant along with economic aspects. These factors need to be studied by looking at the worst possible impact that can result in from a catastrophic emission and also from daily operational conditions in the plant. This paper presents a methodology that can be used to select process routes during early design stages based on inherent safety, health and environmental friendliness considering impacts due to daily plant operational activities. An integrated index called Inherent Chemical Process Route Index (ICPRI) is proposed. The ICPRI considers the potential toxicological impacts on the environment and on the occupational health and the potential chemical and process safety impacts within the plant. A lower ICPRI value indicates a more inherently environmentally friendly, inherently occupationally healthy and inherently safer process route. The ICPRI is tested on four routes to produce acetone. The propene oxidation route showed the lowest ICPRI value indicating having the lowest hazard among potential chemical process routes based on the inherent safety, health and environment assessment.

Exergy analysis of an industrial-scale ultrafiltrated (UF) cheese production plant: a detailed survey

In this study, a detailed exergy analysis of an industrial-scale ultrafiltrated (UF) cheese production plant was conducted based on actual operational data in order to provide more comprehensive insights into the performance of the whole plant and its main subcomponents. The plant included four main subsystems, i.e., steam generator (I), above-zero refrigeration system (II), Bactocatch-assisted pasteurization line (III), and UF cheese production line (IV). In addition, this analysis was aimed at quantifying the exergy destroyed in processing a known quantity of the UF cheese using the mass allocation method. The specific exergy destruction of the UF cheese production was determined at 2330.42 kJ/kg. The contributions of the subsystems I, II, III, and IV to the specific exergy destruction of the UF cheese production were computed as 1337.67, 386.18, 283.05, and 323.51 kJ/kg, respectively. Additionally, it was observed through the analysis that the steam generation system had the largest contribution to the thermodynamic inefficiency of the UF cheese production, accounting for 57.40 % of the specific exergy destruction. Generally, the outcomes of this survey further manifested the benefits of applying exergy analysis for design, analysis, and optimization of industrial-scale dairy processing plants to achieve the most cost-effective and environmentally-benign production strategies.

Create a firm process safety foundation for your new facilities

Documented here is the acceptance speech of the 2015 Norton H. Walton‐Russell L. Miller Award of the Safety and Health Division of AIChE. The award was presented to Dr. Victor H. Edwards at the annual division banquet at the Global Congress on Process Safety in Austin, TX on April 28, 2015. The speech emphasizes the crucial role that process safety should play in the concept, siting, and design of process plants. © 2016 American Institute of Chemical Engineers Process Saf Prog 35: 258–259, 2016

Utilization of Renewable Energy Sources for Drying Medicinal and Nutritional Plants in Panama

This research study looked at the design, construction, running and evaluation of an artisanal processing plant or factory that included a solar oven to capture the thermal energy for drying medicinal and nutritional plants. The use of renewable resources, especially solar energy plus a minimum of technological equipment and attention to principles of quality, hygiene, and future sustainability, contributed to the success of this engineering project. The factory was located in the rural community of El Cacao, District of Capira, Province of Panama, Republic of Panama, Central America. An indirect solar oven represented the center of the operation of the factory. Tests with locally grown plants including oregano (Origanum vulgare), coriander (Coriandrum sativum), rosemary (Rosmarinus officinalis), balsamino or bitter melon (Momordica charantia) and lemongrass ( Cymbopogon citrullus), were conducted to measure the heat transfer and conductivity from the oven to the drying room. We also conducted an organoleptic study with community members to assess dried lemongrass as tea vs. a commercial tea . Preliminary tests with medicinal plants showed the efficiency of the factory in drying with significantly lower times than those found in the literature, obtaining the recommended humidity percentages. In addition, the organoleptic features of the lemongrass tea were rated as with more acceptable features as compared with the commercial lemongrass tea. The preliminary findings reported here are promising and, from the reception from community members, it is expected that they will accept the products being developed for them. The goal is for this and similar communities to have better and more permanent access to their traditional nutritional and medicinal plants.

Integrated Process and Plant Design Optimisation of Industrial Scale Batch Systems: Addressing the Inherent Dynamics through Stochastic and Hybrid Approaches

This work explores stochastic and hybrid solution approaches for dealing with the problem of integrated batch process development and plant design. The simultaneous optimization of batch process synthesis, task allocation and plant design has been formulated in the literature as a mixed-logic dynamic optimization (MLDO) problem, including dynamic control profiles, continuous variables, integers and Booleans as degrees of freedom. In industrial scale situations, this formulation leads to numerically intractable problems when mathematical programming solution strategies are used. So, this work presents a 2-step approach that combines a differential genetic algorithm (DGA) with a deterministic directsimultaneous solution that transforms the problem into a non-linear programming (NLP) problem. The core idea is to combine in the DGA chromosomes the multiple decisions that characterize the problem, and then to use the solution obtained for reducing the complexity of this highly non-linear problem, so it can be managed by standard deterministic solvers. A comparative study of the stochastic and hybrid strategies with the purely deterministic solution is made for the specific case of primary copolymerization for acrylic fibre production. The results show that local optimal solutions of the deterministic method can be beaten by the proposed optimization strategy, becoming a suitable option for solving cases of industrial size.

Evaluation of Banded Iron Formation using Magnetic Susceptibility

In a banded magnetite deposit where assays gave no indication of concentrate yield, information required for process plant design was derived from downhole magnetic susceptibility logs.Early analysis showed poor correlation between Davis Tube Recovery (DTR) and downhole magnetic susceptibility. The role of anisotropy in this relationship was identified and a correction factor applied to bring all data to an equivalent core to bedding angle. The result was a very high definition measure of in-situ magnetite distribution from which product yield estimates could be made.The definition of ore type according to magnetic susceptibility profile enabled the content of potential Run of Mine ore to be characterised. Information required for front end plant design relating to economic cut-off grade, magnetic separator configuration and waste rock volumes could be estimated at an early stage of project development.The use of geophysical data has now been applied successfully to other banded formations where conventional mining block models fail to deliver the resolution of data required by process engineers.

Analysis of Cryogenic Cycle with Process Modeling Tool: Aspen HYSYS

Cryogenic engineering deals with the development and improvement of low temperature techniques, processes and equipment. A process simulator such as Aspen HYSYS, for the design, analysis, and optimization of process plants, has features that accommodate the special requirements and therefore can be used to simulate most cryogenic liquefaction and refrigeration processes. Liquefaction is the process of cooling or refrigerating a gas to a temperature below its critical temperature so that liquid can be formed at some suitable pressure which is below the critical pressure. Cryogenic processes require special attention in terms of the integration of various components like heat exchangers, Joule-Thompson Valve, Turbo expander and Compressor.Here, Aspen HYSYS, a process modeling tool, is used to understand the behavior of the complete plant. This paper presents the analysis of an air liquefaction plant based on the Linde cryogenic cycle, performed using the Aspen HYSYS process modeling tool. It covers the technique used to find the optimum values for getting the maximum liquefaction of the plant considering different constraints of other parameters. The analysis result so obtained gives clear idea in deciding various parameter values before implementation of the actual plant in the field. It also gives an idea about the productivity and profitability of the given configuration plant which leads to the design of an efficient productive plant.

Inherently safer design review and their timing during chemical process development and design

This paper discusses the enhancement of inherent safety review and its implementation in the chemical process development and design. The aim is to update and improve the existing inherently safer design review (ISDR) practices during design of chemical process plant by exploiting major accident cases from the U.S. Chemical Safety Board (CSB) and Failure Knowledge Database (FKD). Although the basic guidelines to conduct ISDR during design phase are available, however they are too general and incomplete. The review criteria and their best timing for application are still missing. This paper attempts to develop the accident-based ISDR for chemical process plant design. The proposed accident-based ISDR is supported with detail review criteria for each phase of process design. The timing of ISDR application is corresponding to the common design tasks and decisions made in the design project. Therefore, timely design review could be done at the specific design task and the findings help designer to make a correct decision making.

Investigation of Alkaline Hydrolysis in Refractory Linings of Process Plants: A Case Study

In view of the ever-increasing energy needs in the process industry, efficiency enhancements assume critical importance. Refractory linings play a pivotal role in reducing the energy consumption of the process equipment along with ensuring safe and reliable operation of a plant. Owing to the project complexities and installation schedules, refractory-lined equipments are often stored at project sites for prolonged times, leading to non-performance and premature failures. One of the main reasons for such failure, especially for plants in the vicinity of a seacoast, is alkaline hydrolysis or carbonation of refractory linings. In this paper, we have investigated the advent and nature of alkaline hydrolysis in a refinery plant. Innovative remedial measures were successfully implemented to prevent further refractory degradation and salvage already affected linings. We have also developed guidelines and proactive techniques that can be applied to the design, engineering and installation stages of up-coming process plants to prevent this problem.