Front End Engineering and Design of Alumina refinery

Hi Friends,

In previous post, we have already discussed about various stages of design and engineering for execution of Alumina refinery project. Engineering activities carried out at Front end engineering and design (FEED) stage is also referred as Front end loading-3 (FEL-3). A few organizations call this stage of design and engineering as preparation of Detailed project report (DPR). In present post, we will share our experience pertaining to list of data, information, design and engineering activities carried out during FEED / FEL-3 / DPR stage of Alumina refinery project as outlined below-

• Characterization of bauxite,
• Firming up plant capacity with provision for expansion,
• Product-mix finalization,
• Selection of process technology,
• Removal of impurities for liquor purification,
• Fixation of process efficiency parameters,
• Optimization of process control parameters,
• Freezing the process flow sheet,
• Unit area-wise PFDs,
• P&IDs,
• Process simulation,
• Material balance,
• Energy balance,
• Water balance,
• Steam and condensate balance,
• Caustic soda balance,
• Unit area-wise electrical energy requirement,
• Specifications of all input materials,
• Specific consumption factors,
• Equipment list and their specifications,
• Equipment data sheets,
• List of pipes with sizes and MoC,
• List of valves with types and MoC,
• List of LT and HT drive motors,
• Finalization of plant site,
• Specifications for Geo-technical studies of soil,
• Development of plot plan and shop layouts,
• Assessment of required infrastructure,
• Preliminary drawing of piping network,
• Single line diagram,
• Specifications of power distribution system,
• Process control philosophy,
• Specifications of instruments and controls,
• Instruments data sheets,
• Development of site grading drawings,
• Estimated volume of cutting, filling and requirement of borrowed earth,
• Design of civil buildings and equipment foundations,
• Design drawings for structural buildings and supports,
• HAZID and HAZOP studies,
• Design configuration of co-generation plant,
• Emergency power supply system,
• Environmental management system,
• Laboratory facilities for routine and non-routine analysis,
• Estimated manpower requirement for operation,
• Budget estimates,
• Project execution methodology,
• Project implementation schedule.

Hope, I have outlined all major activities covered under FEED stage of Alumina refinery project. Please put your views / suggestions / remarks / comments, if any.

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Thanks and regards.

Kunwar Rajendra