Facility Layout Optimization of an Ammonia Plant Based on Risk and Economic Analysis

Recent advances in the chemical process industry have allowed for the intensification of reactors and unit operations, by enhancing heat and mass transfer or combining multiple unit operations. Process intensification can enable chemical plants to be constructed in a more compact, modular fashion, offering improvements over conventional on-site approaches to capital construction, operations and maintenance. This modular chemical process intensification (MCPI) offers several benefits over conventional stick-built (CSB) plant construction in terms of reduced footprint, reduced energy consumption, lower cost, less waste and improved safety and quality control.However, acceptance of MCPI over CSB construction practices within the chemical industry can be impeded by the uncertain risks associated with investing in new technology. The work here documents a case study during the development of a modular chemical plant for capturing distributed energy resources within chemical production. This MCPI approach to plant construction is contrasted with a CSB approach for producing the same chemical product. Data collection tools were developed, based on a literature review, and data was collected from the technology developer to understand the process technology. Sensitivity analysis was then conducted to analyze the business rationale for the application of MCPI over CSB across several market scenarios. It was found that MCPI would be better suited for capacities up to 150 000 metric tons per year, but that improvement in payback period was needed.Additionally, for MCPI approach to achieve acceptable payback periods, efforts are needed to reduce the cost of capital equipment and compress the schedule for ramping up modular production.

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“…Plant footprint 8 trains of 5 modules (53 0 Â 8.5 0 ea.) = 18 020 ft 2 140 985 ft 2 [24] Learning rate by numbering-up…”

Section: Full Capacity In 3 Yearsmentioning

confidence: 99%

Economic risk analysis for the capture of a distributed energy resource using modular chemical process intensification

Raman

Haapala

O’Connor

et al. 2021

J Adv Manuf & Process

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“…Typically, the plant layout analysis is performed at later design stages of process lifecycle (Brunoro Ahumada et al, 2018). There are a number of research works available in the literature to propose the plant layout, for example, cost and safety aspects for plant layout by genetic algorithm (Caputo et al, 2015), mixed integer nonlinear programming (MINLP) (Latifi et al, 2017), mixed integer linear programming (MILP) (Guirardello and Swaney, 2005;Patsiatzis et al, 2004;Rahman et al, 2014) and mixed integer optimization (MIO) (Xu and Papageorgiou, 2009). Although the MILP approach has been recently applied for the layout of storage vessels at the design stage (de Lira-Flores et al, 2018), it is not clearly defined whether the design stage is preliminary, basic or detailed.…”

Section: The Distance Between Process Equipmentmentioning

confidence: 99%

Process equipment common attributes for inherently safer process design at preliminary design stage

Athar

Shariff

Buang

et al. 2019

Process Safety and Environmental Protection

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“…At first the critical equipment were selected. These units were chosen based on their operating conditions and reported accident frequencies [24].The units are, namely, the ammonia converter, primary reformer, secondary reformer, urea synthesis reactor and high pressure stripper. The objective is to evaluate whether facilities, such as, control room or operators' shelters are safely sited with respect to these critical units.…”

Section: Case Study: Evaluation Of Facility Siting Of An Existing Ammmentioning

confidence: 99%

Risk Map for Facility Siting of an Ammonia-Urea Complex

2017

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Abstract:In this study safer facility siting of an ammonia-urea complex is demonstrated by risk mapping. This risk map is useful for identifying safer zones within the plant at the design stage as well as before setting temporary shelters, i.e. shelters for contractors and maintenance workers etc. in an existing plant. To prepare the risk map a number of critical process units of an ammonia-urea complex are selected as the sources of toxic release and blast overpressure. Locations of control room and three operators' shelters are considered with respect to five critical units. Consequences of toxic release and blast overpressure are modeled for various worst case scenarios developed in the critical units. Both structural damage and human mortality/injury are converted into risk scores. Risk mapping of the battery limit area are done and locations with minimum risk scores within plant area are identified for the probable siting of the control room and operators' shelters. The findings are compared with the layout of an existing ammonia-urea complex. It is also shown that a simple risk mapping of the plant area is helpful in avoiding facility siting in high risk zone at the same time finding safer locations for different facilities.

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Facility Layout Optimization of an Ammonia Plant Based on Risk and Economic Analysis

Cited by 24 publications

References 6 publications

Economic risk analysis for the capture of a distributed energy resource using modular chemical process intensification

Economic risk analysis for the capture of a distributed energy resource using modular chemical process intensification

Process equipment common attributes for inherently safer process design at preliminary design stage

Risk Map for Facility Siting of an Ammonia-Urea Complex

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