Page 14 - Design of Simple and Robust Process Plants

Design of Simple and Robust Process Plants. J. L. Koolen XV
Copyright 2002 Wiley-VCH Verlag GmbH & Co. KGaA
ISBNs: 3-527-29784-7 (Hardback); 3-527-60047-7 (Electronic)

Preface

My experiences in the process industry during the past decade led me to write a
book about the design of simple and robust process plants which include reliable,
hands-off operation. There was,I felt,a clear short-coming in that nobody had pub-
lished a comprehensive work covering this subject ± a somewhat surprising finding
since the benefits of such a designed process are huge,with capital savings on the
order of 30±40% achievable compared with a conventionally designed process.
Moreover,operational savings can also be achieved by minimizing operational per-
sonnel and improving the quality of operation. A limited number of reports have
been made on process intensification which address the concept from a unit per-
spective. The present book tries to create a total picture of how the design of a truly
competitive process should be approached,from process design through control
design to operation.
One question which I have to answer quite often is,ªWhy do you think now is the
right time to introduce this conceptª? The answer must lie in the progress that has
been made in technology:
. The mechanical design of equipment has been improved by better design
details. Of special mention here is the drive to minimize or eliminate
mechanical contact,for example the introduction of gas seals first for com-
pressors,and currently for pumps. Screw compressors have been introduced
with synchronized,separate electric drives for both screws in order to avoid
metal-to-metal contact of the gears. Another example of avoiding mechanical
contact is in switch design,these being changed from mechanical to induc-
tive types. Next to other mechanical improvements,these designs have been
improved over the years,and resulted in more reliable components with
longer stand times so that maintenance could be minimized and times
between shut-down for mechanical reasons increased. This is one reason
why the philosophy ªDesign for single components unless ¼º is introduced.
. Process technology has improved by means of simplification and intensifica-
tion. During the past few decades,progress has been made to minimize
equipment,improved logistic operations have been applied,storage has been
reduced,and the quality operation has been improved to avoid off-spec facil-
ities. In addition,several functions have been combined into one vessel,for