SHRDC Class Problem Plant Data Adapted from Plant Layout Module: Lecture 3 -Producing the Layout Illustration

of the Formal Method By James Madden Zyqad Ltd Suite 25 GPT Business Park Technology Drive Beeston Nottingham NG9 2ND J Madden, July 1999

1. Introduction
In this illustration, we shall consider a small chemical plant containing batch and continuous operation, with a wide variety of equipment types and flow regimes.

2. The Plant
The process and equipment information is presented below. Key layout conditions to be observed are: The plant will be housed in a structure with hot areas open to the elements and quality controlled areas protected from contamination. Site conditions demand that the raw materials feed and product discharge are on opposite sides of the structure. The dry raw material loading and final product bagging area are to be protected from the elements by a building enclosure

3. Process Description
The plant shown on the Block Diagram and Flowsheet, Figs 1 and 2 is to produce 4000 tonnes per year of polymer (notionally polyvinylidene chloride) from monomer. It is loosely based on a plant built by a major manufacturer and changes have made to protect commercial information. The changes make the process as described impractical for production purposes, but do not affect the practicality of the layout. The reaction is conducted in an acetone/water solution in the stirred tanks R104, R108 and R112, taking eight hours to complete. The reactors are charged, in turn, every three hours from the weighing tanks T101 (water), T102 (make-up monomer) and T103 (acetone, both fresh and recycled, and recycled monomer). The reaction is catalysed by a consumable organic salt, injected to the reactors by the metering pumps P107/111/115. Primary control of the reactors is by control of the catalyst feed rate. The reaction is rapid and highly exothermic and heat is removed by boiling off large volumes of Acetone (and, in the initial stages, some Monomer) which is condensed in the water cooled reflux condensers H105, H109 and H113. These are large single pass on both sides and horizontal to increase their efficiency and thus reduce their size. The liquid hold up in the condenser circuit must be minimised to maintain reactor composition and the critical reaction temperature within controllable conditions. Catalyst solution is made freshly for each batch in the stirred tanks T106, T110 and T115. It is injected into the reactors by metering pumps P107, P111 and P115 to control the reaction rate. The reactor discharge, a slurry of polymer in an Acetone/water suspension, is transferred via the mono pump, P116, to the filter feed tank, T117. The slurry, containing 10% of both polymer and monomer is recirculated through the feed trough of the vacuum filter, F119, wherein the level is controlled by a weir, the excess being returned to T117. Filtrate and entrained air are separated in T120. The air is withdrawn by the ejector, P121, to maintain the reduced pressure necessary for the operation of the filter.

The filtrate - containing the unused monomer and initiator, the Acetone/water from the reactor and wash water - is heated in H123 then distilled in column C124. This ensures that the acetone and monomer, recycled to the acetone weighing tank, T103 are free of initiator. The water and any unused initiator it may contain is discharged to effluent. The filter cake from F119 is dried in the co-current rotary drum drier, D129, which operates at a slight positive pressure. The dryer is operated with sufficient air to keep the Acetone/Monomer content of the exit foul air below the LFL. The air for the drier is heated by steam in H134 and is blown through the drier by P133. Entrained polymer in the exhaust air is removed in cyclone X132 and returned to V130. The dried polymer is held in hopper V130 until fed to the bagger/palletiser X131. The palletiseds product is transferred to the existing warehouse by forklift truck. All pumps have standbys (not shown on the flowsheet). All utilities are generated outside the battery limits. Basic equipment and stream data is attached.

Item Number Description Number Off Dimns. rate or capacity Analysis of material handled Mass % Material Working pressure Working temp. degrees C Services Remarks

T101 Water weigh tank 1 1700 dia x 2000 water 100%

T102 Monomer weigh tank 1 1700 dia x 1600 Monomer 100%

T103 Acetone weigh tank 1 1900 dia x 2100 Acetone 84% Monomer 16% Stainless Atmos Ambient None Mounted on load cells

R104,108,112 Polymerisation reactors 3 2700 dia x 3000 Acetone 50% Monomer 10% Polymer 10% Water 30% Stainless Atmos 30 Cooling water power

H105,109,113 Reflux condensers 3 tube length 5.0 m shell dia. 1.14 m Acetone 100%

T106,110,114 Initiator make-up tanks 3 400 dia x 1200 Water 90% Initiator 10% Stainless Atmos Ambient Power

GRP Atmos Ambient None Mounted on load cells

Stainless Atmos Ambient None Mounted on load cells

Mild steel Atmos 30 Cooling water

Glass fibre-reinforced polyester (GRP) composites are the most popular reinforced plastic materials used in the construction industry

Item Number Description

Number Off Dimns. rate or capacity Analysis of Water 90% material handled Initiator 10% Mass % Material Working pressure Working temp. degrees C Services Remarks Stainless Atmos Ambient Power

P107,111,115 Initiator met. pumps 3 4.8 1/min

P116 Reactor discharge pump 1, 1 standby 0.6 m**3/min Acetone Water Polymer Monomer Stainless 2 bar g 30 Power Suffers abrasion 50% 30% 10% 10%

T117 Filter feed tank 1 14 m**3 working vol. Acetone 50% Water 30% Polymer 10% Monomer 10% Stainless Atmos Ambient Power wash water

P118 Filter feed pump 1, 1 standby 3.04 1/s Acetone 50% Water 30% Polymer 10% Monomer 10% Stainless 2 bar g Ambient Suffers abrasion

F119 Rotary vacuum filter 1 96 m**2 filter area Acetone 50% Water 30% Polymer 10% Monomer 10% Stainless body nylon cloth 0.27 bar abs Ambient

T120 Filtrate gas/liquid separator 1 Length 2.5 m Dia 1.4 m Water 66.4% Acetone 27.9% Monomer 5.7% Mild steel 0.23 bar abs Ambient Power

Item Number Description Number Off Dimns. rate or capacity Analysis of material handled Mass % Material

P121 Ejector 1 2.20 m***3/s Air 90% Acetone 10% Mild steel

P122 Filtrate pump 1, 1standby 3.16 1/s Water 66.4% Acetone 27.9% Monomer 5.7% Stainless 2 bar g Ambient Power

H123 Column pre-heater 1 3.16 1/s Water 66.4% Acetone 27.9% Monomer 5.7% Stainless tubes Mild steel shell 4 bar g 2 bar g Shell 140 Tube 60 LP steam

C124 Acetone column 1 Dia. 550 mm 3 tray modules 3000 high Water 66.4% Acetone 27.9% Monomer 5.7% Stainless Atmos Atmos Trayed

H125 Column condenser 1 Tube length 2.4 m Shell 0.54 m Acetone 83.3% Monomer 16.7% Mild steel Atmos Atmos Cooling water

Working pressure 4 bar g 0.2 bar abs Working temp. 140 degrees C Services LP steam Remarks

Item Number Description Number Off Dimns. rate or capacity Analysis of material handled Mass % Material Working temp. degrees C Services Remarks

T126 Column reflux drum 1 1.3 m**3 liquid Total vol. 3.8 m3 Acetone 83.3% Monomer 16.7% Mild steel 47

H127 Column reboiler 1

P128 Overheads pump

Water 97.6% Acetone 2.0% Monomer 0.4% Stainless 60 LP steam Vertical thermosyphon

D129 Product drum dryer 1, 1 standby 1 1.1 l/s Drum length 8.3 m Drum dia. 1.5 m Acetone 83.3% Air 95% Monomer Water 3% 16.7% Polymer 2% Mild steel Mild steel 47 100 Power Power Dust explosion hazard

V130 Product hopper 1 10 m**3 working vol. Polymer Mild steel Ambient Dust explosion hazard 100%

Item Number Description Number Off Dimns. rate or capacity Analysis of material handled Mass % Material Working pressure Working temp. degrees C Services Remarks

X131 Bagger/palletiser 1 8.3 kg/s Polymer 100% N/A N/A N/A Power Operated one 8 hour shift per day

X132 Cyclone 1 7.73 m**3/s Air 94.5% Water 5% Polymer 0.5% Mild steel 0.03 bar g 40 Dust explosion hazard

P133 Blower 1 7.73 m**3/s Air 95% Water 5% Mild steel 0.06 bar g 40 Power

H134 Air heater 1 7.65 m**3/s Air Mild steel 0.06 bar g 100 LP steam 100%

Plant Layout Example

Fig. 1

Raw Material IN

R F
Product OUT

Hold

Hold

Air Out

Water to Drain

Air In

Block Diagram - Batch Polymer Plant

FMPFig01

Formal Method Problem Batch Plant Process Flowsheet

Acetone in Recycle Acetone T102 T103 T126 H105 H109 H113

Monomer in Water in T101

Fig. 2
H125

Catalyst Bags T106

R104 T110

R108 T114

R112 C124 Polymer Slurry P128

P107

P111

Exhaust Air X132 Polyme r Powder V130 Air In Bagged Polyme r Out P133 X131 D129 H134

Polyme r Paste

P115

P116

F119 T117 T120

H123

H127 P121 HP Stea m P11 8 Condensate To Effluent P122 Water to Effluent

FormMethProbFig02

10

11

MAJOR ITEM SKETCHES R104 - C124 - F119

Fig. 9

550 Dia R-104/-108/-112 11 50 0 T/ T 2200 1, 75 00 0 0 Column C124 1000 2000 500 750 4,500 Filter F119
FormMethAnsFig0 9

4,500

2700 Dia

3000

1000

75 500 0

12

MAJOR ITEM SKETCHES R104 - C124 - F119

9300 Long Outlet Box 900 X 2600 Inlet Box 1100 X 2600

Fig.1 0

1500

1500 Dia Drive Unit below Drum Dryer D129

2800

Hopper V130 Cyclone X132

4000

2500

Bagger X131

Bagged Polymer Out

2000

3500

2000 Dia

3800

1000 Dia

1500

1800

FormMethAnsFig10

13

14

COLUMN GROUP ELEVATIONS

H125

Fig, 12

19570 el

540 dia 1000 piping T126 1400 dia

2500 to drive Control Valve 500

14400 el

9000 Packed Height

C124

1000 2400 Tubes 1500

FormMethAnsFig1 2

Liquid level 3900 el 500 Liquid Depth H127 Ground level

15

REACTOR GROUP ELEVATIONS

Fig, 11

H105 (1140
DIA)

T101/2/ 3

1000 6670 el

1500

5600 el

R10 4

3000

2000 Ground Level 600

FormMethAnsFig11

P10 6

16

DRYER GROUP ELEVATIONS

Fig. 13

F119 X132 10500 el 40 0 D129 1000 Min V130 50 0 380 0 50 0 250 0

17

10100 el 180 0

7300 el

Minimum pipe angle 45 Note effect of horizontal offsets from sloped pipes.

X131

Ground Level

FormMethAnsFig13

VACUUM GROUP ELEVATIONS

Fig. 14

10200 el

P121 T120

F119 10600 el 800 for good pipe slope 700 Dia 9100 el

Presure 0.27 Bar Abs 9000 Min Barometric Seal 8500 Min Barometric Seal

Ht 1200 Seal Tank

Ground Level

P122

600

FormMethAnsFig1 4

18

ASSEMBLING GROUP LAYOUTS INTO PLANT

Fig. 17

RAW MATLS IN

FEED TANKS R10 4 R10 8 R11 2

COLUMN

DRYER

F11 9

AIR (Under) PRODUCT OUT

VACUUM

GROUP ASSEMBLY - Not to scale

FormMethAnsFig1 7

19

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