MAJOR ENGINEERING & EXECUTION ACTIVITIES FOR SETTING UP NEW CHEMICAL INDUSTRIES

Hi Friends,

Before going through the current article, you will like to have a look at "Caustic embrittlement in Alumina Refinery". This will help you to know the impact of caustic at high temperature.

As such it is difficult to list out major engineering and execution activities, however all out efforts have been made to assimilate the information in systematic manner for guiding the young professionals engaged in engineering of Mineral processing / Specialized Chemical Industries as outlined here under-

A.      Pre-Project Activities

1.       Finalization of Product mix

2.       Quality specifications of products

3.       Preparation of Conceptual Report

4.       Technological testing of  input materials

5.       Site selection and land acquisition

6.       Identification of available infrastructure like roads, rails, rivers and port facilities

7.       Estimation of Raw material consumption factors

8.       Estimation of utilities requirement like steam, power, chilled water & compressed air

9.       List of major equipment with broad specifications

10.   Estimation of Capex and Opex

11.   Development of Plot plan

12.   Preparation of Feasibility Report

13.   EIA / EMP Report

14.   Statutory clearances for site

15.   Receipt of Consent to Establish (CTE)

B.      Basic Engineering

1.       Process Design Basis

2.       Fixing the process & operating parameters

3.       Material flow balance

4.       Thermal energy balance

5.       Water Balance

6.       Caustic Balance

7.       Alumina Balance

8.       Condensate balance

9.       Development of  Overall Process Flow Diagram

10.   PFDs for All Units

11.   P&IDs for All Units

12.   Broad specifications of major technological equipment

                                                 i.       Primary & secondary crusher

                                                ii.      Conveyors

                                              iii.      Vibro-pulse screens

                                              iv.      Ball mills

                                                v.       Slurry pumps

                                              vi.      Heat Exchangers

                                            vii.       Autoclaves / Digesters

                                           viii.      Flash Tanks

                                              ix.       Evaporators

                                                x.      PHEs

                                              xi.       Boilers

                                             xii.      Compressors

                                           xiii.       Cooling Towers

                                           xiv.      Rotary Disc Filters

                                             xv.      Rotary Drum Filters

                                           xvi.      Calciners

13.   List of major equipment with motor ratings

14.   Specifications of other process equipment

15.   Instrumentation and control philosophy

16.   List of cranes and hoists

17.   Sizing of heat exchangers

18.   Sizing of Desilicators

19.   Sizing of Liquor decanters & washers

20.   Sizing of Precipitators

21.   Sizing of condensate & other liquid storages tanks

22.   Specifications for liquor and water pumps

23.   Sizing of pipelines

24.   Sizing of valves

25.    Acid cleaning system for heat exchangers

26.   Chemical cleaning system for precipitators

C.      Detailed engineering

1.       Preparation of tender documents

2.       Development of General layout of the plant

3.       Preparation of shop layout

4.       Assistance in evaluation of offers

5.       Assistance in inspection of equipment

6.       Assistance in procurement of plant & equipment

7.       SLD for Power Control Centre (PCC)

8.       SLDs for Motor Control Centre (MCC)

9.       Design of Digesters

10.   Design of Flash tanks

11.   Design drawings for tanks and vessels

12.   Inspection and expediting activities

13.   Drawings for process & utility piping network

14.   Design drawings for Civil & Structural Buildings

15.   Foundation drawings for all equipment & facilities

16.   Certification of bills payable to contractors and suppliers

D.      Construction activities

1.       Preparation of schedule of activities

2.       Planning for materials, machines and manpower

3.       Planning of construction activities

4.       Appointment of Competent Contractors

5.       Supervision of construction at site

6.       Cost & quality control during erection

E.       Assistance in Testing & Commissioning

1.       Checking Mechanical completion

2.       Cold trial run

3.       Hot trial run

4.       Commissioning of equipment

5.       Plant commissioning procedure

6.       Performance guarantee test

F.       Stabilization of plant

1.       Finalization of  process and operating parameters

2.       Guiding the team for steady  plant operation

G.      Quality control methodology

H.      Safety and Environmental Management & Control Techniques

I.        Preparation of As-Built Drawings.

The above list clearly indicates the volume of engineering and execution activities involved in putting up any new chemical industries in any geographical location across the globe. 

Also, you may be interested to read our paper on "Systematic approach on testing and commissioning of Newly Constructed Alumina Refinery" .

We  will welcome your feedback and suggestions for further improvement. 

For any assignment related to design and engineering activities, we may be contacted at rajendra@ceti.co.in. Details of services are available at our website.
Best regards.

Rajendra Kunwar
India
www.ceti.co.in