Page 79 - Design of Simple and Robust Process Plants

3.4 Design Philosophies are an Integrated Set 63
3.4
Design Philosophies are an Integrated Set

The above ten design and operational philosophies are to be seen as an integrated
set of philosophies. The impact and integration as an example of the evolution of
the batch plant is illustrated in Chapter 1 (Figures 1.4±1.7). By comparing the differ-
ent generations of plant with the final design, the following application of philoso-
phies can be identified:

. Inherently safer design
± Avoidance of opening of equipment
± Elimination of hydrocarbon hydro carbon (HC) storage by direct feed to avoid
inventory of hazardous material
± Elimination of HC mix tanks by in-line mixing to avoid problems of reactive
chemicals and storage of hazardous materials.
. Environmentally sound
± Vent recovery.
± Elimination of HC storage prevents loading and breathing losses.
± Less product storage prevents product leakage.
± Less handling of additives prevents spills.
. Minimize equipment
± Elimination of HC storage tanks by direct feed.
± Elimination of HC mix tanks by in-line mixing.
± Replacement of additive tanks with dedicated containers.
± Avoidance of more reactor trains by development of large reactor system.
± Avoidance of lot tanks by improved feed forward control.
± Elimination of final product tanks evolved through basic product storage in
storage containers.
± Elimination of post reactor and devolatilization vessel by finishing in the
reactor.
± Elimination of product cooler by cooling in reactor vessel.
± Vent condenser included in overhead condenser.
. Design for single reliable components
± Single reactor train.
± Pumps to be single, not shown on the flowsheet.
. Optimize design
± Application of design philosophies as single component, minimize equip-
ment, etc.
. Clever process integration
± Integration of supplier plant by direct feed of HCs.
. Minimize human intervention
± Minimization of batch time by automation.
± Improved feed forward control to improve product consistency to avoid lot
tanks.