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

Design and engineering stages of Alumina refinery

Hi Friends,

In present post, we will elaborate the various stages of design and engineering for successful execution of any Alumina refinery project. There are four stages of design and engineering as described in subsequent paragraphs-
1. Conceptual design: This is the initial stage of plant design wherein design basis is developed on the basis of estimated bauxite reserves, mineralogical composition of bauxite, availability of infrastructure, probable location of refinery, site information, meteorological data, technological options, process route, cost estimates and financial analysis are worked out to have the indicative figures on capex, opex, IRR and pay back period. This stage is also known as pre-feasibility / feasibility stage or Front-end loading-1/ Front-end loading-2 (FEL-1 / FEL-2) of the project. It is the pre-project planning stage of the project. At this stage, the accuracy in cost estimates is generally + 20% as equipment price data are generally based on norms of industry standard. This study gives fair idea of returns on investment for taking decision to go ahead further. Promoter driven organizations find this document adequate for their path forward, however, Public sector organization and Word bank funded projects require further studies / reports like DPR / FEED, as detailed below, to reaffirm the feasibility of the project with improved accuracy level of projected financial figures.
2. Preparation of basic design package : This is the next stage of plant design prepared on the basis of bauxite reserves, project site details and inputs received from process technology supplier. This document is also known as  Detailed project report (DPR) as it covers over 50% of engineering activities for execution of the plant. At this stage almost all technical figures are firmed up. This stage is also known as Front-end engineering and design (FEED) or Front-end loading-3 (FEL-3) by engineering consultants of different parts of the globe. FEED is the critical stage of the project for successful execution of Alumina refinery. FEED includes broad specifications of equipment and facilities for getting quotations. It gives clear understanding of key economic and risk factors of the Alumina refinery project. At this stage, the accuracy level in financial figures is +10% as it is developed based on detailed working backed by budgetary quotations from equipment suppliers.
3. Development of basic engineering: Since FEED document is prepared based on preliminary basic engineering data supplied by technology supplier, thus it becomes the basis for development of Basic engineering. At this stage, all process, design and engineering data are fine tuned, firmed up and finalized. Size and capacity of all equipment and facilities are worked out precisely with utmost accuracy on the basis of outcome of process simulation analysis. Design criteria, safety aspects and environmental management issues are addressed in detail with clarity. Each and every data covered in FEED document are checked, modified if required and frozen with utmost care and accuracy. Basic engineering document is the final design and engineering document for carrying out detailed engineering to initiate procurement activities. 
4. Detailed engineering: Design and engineering document developed during basic engineering stage is translated in detail incorporating required services, utilities and other aspects as earmarked in basic engineering document for completeness of specifications vis-a-vis tender document for procurement of equipment and facilities for setting up Alumina refinery. Working drawings are developed matching equipment dimensions and their locations in plant area. Preparation of design drawings and fabrication drawings for structural work is done at this stage only. Adequate working space is kept in mind for easy movement of man and machines  safely. Detailing of material handling system, power distribution, instrumentation and controls, fire fighting and facilities for pollution control are carried out at this stage of project for successful implementation.
Activities stated under serial number-2 and 3 are engineering (E) part and those described under serial number- 4 are procurement and construction (PC) part of so called Engineering, procurement and construction (EPC) methodology of project. Method of managing all three activities together is popularly known as Engineering, procurement and construction management (EPCM) of Alumina refinery project. We will discuss the list of activities covered under each stage of design and engineering of Alumina refinery in forthcoming posts.

Please come forward and indicate your views / remarks / comments, if any.

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Kunwar Rajendra