Construction of a Chemical Plant

wrench of a Chemical PlantSITE CONSIDERATIONS 5.1 Summary In this chapter, the purpose is to stop a clear view on the selected attitude on with the reason, ex final cau seation and the brief information just about the web state of affairs as whole nigh in order to construct a chemical trifleings. The master(prenominal) counseling is all about the side consideration, which is to consider the most strategic muddle in terminals of geographical factors. A strategic come out moldiness be found for a stark naked project and the state of affairs and equipment layout fate to be planned to ensure that the show allow for be tend at its best condition to ensure the quality of the occupation of methanol. In addition, there a some factors mustiness be considered first eon selecting a commensurate post such as location, painful bodily come out, violate facilities, availableness of labour, availability of utilities, availability of suitable earth, outflowing disposa l, local community consideration, climate and the last one is politic and economic consideration. As the conclusion, Gebeng industrial region, Kuantan which is hardened in Pahang Darul Makmur was selected as the place for the Iso-amyl Alcohol determine. nett but not least, the full treatment layout is also potn as it is chief(prenominal) in order to consider how the place is grade.5.2 IntroductionA introductory feasibility study must be conducted and a suitable site must be found to begin with start the plant construction. The location of the plant may have a crucial effect on the profitability of the plant and its operation. It is Copernican to determine whether the Iso-amyl Alcohol plant is feasible to be built up or not in term of safety, environment impact controllability, the flexibility for the plant and the economic aspect as s salutary. There atomic number 18 some factor that must be considered before build the methanol plant to make sure the operation wil l operate smoothly and to get the best quality of Iso-amyl Alcohol production such as location of state, raw material supply, revel facilities, effluent disposal, climate, availability of labour, availability of utilities, suitable land, local community and politic and economic. The create of Iso-amyl Alcohol is classified as a petrochemical project. The plant must be situated in a specialized zone gived by government. tether chief(prenominal) locations that have been short listed to set up the proposed 100,000 metric short ton/year Iso-amyl Alcohol plant are Senawang industrial state, Negeri Sembilan, Pengerang industrial porthole, Johor and Gebeng industrial Land in Kuantan, Pahang. The comparison table is given up in conf occasion 5.4.5.3 Side Consideration 5.3.1 Location of Areaindustrial area are typically situated outside the principle neighbourhood of a city. The ply for the most part is given great displaceation get to including lane and rail. Separating the i ndustrial region is to set aside modern uses from urban ranges so as to decreasing the ecological and social effect. It bear likewise draw in more brisk business by giving a coordinated simulation in one area.5.3.2 Raw Materials SupplyThe supply of crude materials is a standout amongst the most inwrought figures choosing the area of a plant. oil color material supply is a critical angle that should be considered before beginning up a plant. As chemical process includes in change of crude materials to complete item, it is essential to have a plant that is situated close to where the supply of crude material is greatest. The principle preferences are to diminish the transportation address of crude material furthermore diminish the capital put re descents into storerooms.5.3.3 Transport FacilitiesTransport facilities are vital for transferral the crude material to the plant and to disperse the completed items to the food market. The basic of transport like street, rail and oce an ought to be accessible and close to the plant. A minor thought is the accessibility of air transport because of the impediment employ of the transport. A decent transport facilities dont just guides the entire mathematical process, however can helps boosting the import and fare exercises. This by one means or other(prenominal) would create great economy for the nation.5.3.4 Effluent DisposalEffluent disposal, be it in fluid, strong or vaporous are a famous worry in planning a plant. There are in truth extreme limitations on waste transfer and these vary with a specific area. It is mandatory to consider the allowable resistance levels for body of water system, land and air dispersal. The site chose make sufficient and successful transfer framework for dealing with the effluents, for example, the oozing frameworks and dumping site. Waste water should be dealt with before diverted to discourteous channels to stay apart from any ecological issues. The cost of the emanating discourse ought to be considered too since ordinarily it will be amply.5.3.5 ClimateIt is essential to settle down the climatological figures around the site region before beginning up a plant. The atmosphere can have a vital intention on the financial operation of a procedure. Malaysia climate profits by a tropical atmosphere with both high temperature and moistness consistently. entropy on the example of precipitation and frequency of high wind or substantial tempests ought to be considered. In selecting a site inside a picked area, the local history ought to be checked first. Any natural consequent like quakes or surge that has been happen should be noted.5.3.6 Availability of childbedThe plant ought to be put in an area where adequate work supply is accessible. Accessible labour from near specialized establishments will give an advantageous commitment to run the plant easily. Despite the fact that the normal pattern is for expanded computerization in concoction plant , notwithstanding staff and designing work force ,the procedure still need a huge work compel, particularly where a move framework in an operation. It is critical for finding the plant to consider the contending businesses, the ability and companionship of specialists and the turnover rate.5.3.7 Availability of UtilitiesUtilities is rate of flowly by and large utilized for the strung-out administrations compulsory in the operation of any production procedure. big businessman indispensable for electrochemical processes, engines, lightings and general utilize. Steam for the procedure warming and it is demand for the procedure is produced in the tube boilers utilizing most monetary fuel. Likewise, water additionally is required for general utilize in light of the fact that the water required for the broadly useful will be taken from nearby source of water.5.3.8 Suitable LandFor the proposed plant and for future extension the appropriate land will be accessible. The land ought to be all around depleted, in an ideally flat and have reasonable load bearing limit. To decide the requirement for other uncommon establishment a full site assessment ought to be made. Moreover, it ought to be accessible with low cost too. To decline the aggregate speculation and development cost, the land cost ought to be heady as could be expected under the circumstances. However, in any case, the land cost relies on upon the area and it might changes without any notice. The area must be safe that it doesnt force extra hazard to the community.5.3.9 Local societyThe plant local group must be able to provide adequate facilities to the plant personnel, for example, schools, banks, lodging and recreational social offices. Other than that, the proposed plant must fit in with and be worthy by the nearby community. Full thought must be given to the protected area of the plant. With that it doesnt force a noteworthy extra hazard to the community.5.3.10 Politic sparingCapital grants, ch arge concessions, and other prompting are regularly given by government to guide new venture to preferred area, for example, areas of high unemployment. The accessibility of such concedes can be the abrogating thought in site selection.5.4 SIDE SELECTION Table 5.4 Side selection betwixt Senawang industrial do of import, Negeri Sembilan,Pengerang industrial appearance, Johor and Gebeng Industrial Land in Kuantan, Pahang.Selection citeria Senawang industrial estate, negeri Sembilan Pengerang Industrial port, Johor Gebeng Industrial land, Kuantan, PahangLocation 5km from Plus HighWay Senawang9km from Lekas Highway13km from Seremban45km from Johor Bharu8km from Johor appearance40km from Kuantan townNext To Palm Oil Industrial Cluster (POIC)Kuantan Port about 10 km away, and Kemaman Port, about 45 km awayTypes of Industries median(a) industryAgriculture industryPetrochemical industryPetrochemical industryArea of useable8.63 hectars12.14 hectarsMin. 3 acres, to max. 250 acres.Land Pr iceRM 12 000 000RM28.00 per square feetRM 36 590 cdRM20.00 per sq.ftRM 2 613 600 for min. 3 acresFeedstockPentane fromShell Refining confederacy (federation Of Malaya) Berhad, Batu 1, Jln Pantai, Port Dickson, MalaysiaChlorine and NaOH fromCCM Chemicals Sdn Bhd(159498-A), dissever PT 200, Jalan Asam Jawa 16/15,Off Persiaran Kemajuan, 40200 Shah Alam, MalaysiaPentane fromShell Refining Company (federation Of Malaya) Berhad, Batu 1, Jln Pantai, Port Dickson, MalaysiaChlorine and NaOH fromCCM Chemicals Sdn Bhd(159498A), Pasir Gudang Factory Plot 411, Kawasan 4 Jalan Perak1 Pasir Gudang Industrial Estate 81700 Johor Bharu, MalaysiaPentane fromShell Refining Company (federation Of Malaya) Berhad, Batu 1, Jln Pantai, Port Dickson, MalaysiaChlorine and NaOH fromMalay-Sino Chemical Industries Sdn Bhd Lot PT 4406, Kawasan Perindustrian Teluk Kalong, 24000 Kemaman, Terengganu, Malaysia.Water SupplySyarikat Air Negeri Sembilan (SAINS)Syarikat AirJohor (SAJ)Semambu Water manipulation PlantEn ergy SourceTNB serembanIPP YTL Powergeneration Sdn.Bhd(404MW)Sultan Iskandar Power stationTNB Johor BharuTNB TanjungGelang, Kuantan. (800Mw)TransportFacilities railroad track principal(prenominal) station bus serembanMain highway to kuala lumpur, port Dickson and Malacca.About 45min from international airport kliaJohor port dependable to jalan kota tinggi main roadFacing Gate 2 Rapid new main road80 km from Johor BahruSultan Ahmad Shah Airport, Kuantan,36km awayKuantan Port about 10 km awayKemaman Port,45 km awayKuantan-Kerteh railroad line Linking the Kerteh Industrial Area and Kuantan Port to its rightOther FacilitiesNearby police force Station and fire stationBankNearby to seremban city butt boats and ferry operate between Changi Point Ferry Terminal (Changi Village) and Pengerang daily.Kuantan-Kerteh rail line Linking the Kerteh Industrial Area and Kuantan Port to its right.5.5 PROPOSED SITE 5.5.1 PROPOSED SITE Figure 5.5.1 The proposed site of plant in Gebeng Industrial Land , Kuantan PahangFigure 5.5.2 The proposed site of location plan in Gebeng industrial land via google image.Figure 5.5.3 The proposed site plan of plant location in Gebeng industrial land via constructed mapAfter doing some consideration based on several factors, Gebeng Industrial Land, Kuantan, Pahang had been choosed due to its matched advantages compares to Senawang Industrial Estate, Negeri Sembilan and Industrial Port Pengerang, Johor for iso amyl alcohol plant setup and production. fetching the best economic scenario into account the plant life, the location have been elect based on several criteria such as operational cost, market outlay , the availability of raw material sources, transportation and capital cost.Gebeng Industrial Land is prepared land ready with infrastructure, located In Gebeng Industrial estate, the main industrial area in Kuantan, Pahang. The Gebeng Industrial Land is a thriving hub of commercial activity where numerous multinational corporations in the petrochemical welkin are based at.Generally, industrial land must be single(a) and of regular shape, completely flat, close to industrial power, water and drainage supplies, and advantageously serviced by transportation infrastructure. Therefore, it is identified to fulfill all the characteristics needed for the proposed site of constructing this petrochemical plant, which is Iso-amyl alcohol plant. The main reason for the selection is the availability of land with availability from 3 acres to 250 acres with the price about RM 20.00 per sq. ft which is affordable price with strategic location.Furtheremore, with a great development phases there, it was located strategically which is located next to Palm Oil Industrial Cluster (POIC) and in close proximity to the Malaysia-China Kuantan Industrial Park (MCKIP). Besides that, it also located only nearby to Petronas Gas Berhad Centralised Utility Facility (PGB CUF) and Gebeng Railway Yard that located to its left side. Moreover, the Kuantan-Kerteh Railway that linking the kerteh industrial area and Kuantan Port only located to its right making this land more strategically to build our plant there.The availability of raw material nearby the plant are suitable for the production in terms of saving the cost operation. Basically, the raw material was supplied by two suppliers which is one from Port Dickson and another one from Kemaman, Terengganu. Shell Refining Company (federation Of Malaya) Berhad in Port Dickson was chosen to supply pentane and Malay-Sino Chemical Industries Sdn Bhd in Kemaman, Terengganu was chosen to supply chlorine and NaOH to plant. Furthermore, in order to ensure the raw material always in stock, Qingdao easternchem inc located in China also chosen to supply the pentane. Basically, the price of pentane is cheapest in China about 1000 dolar per metric ton, but the total price to supply to plant need to consider likes transportation process of this material. The raw material will be shippin g from China to the port Kuantan, Pahang in bulk quantities. Then the material will be send by cargo truck services from port to the plant.Besides that, the transport of materials and products to and from the plant will be an overriding consideration in site selection. If practicable, a site should be selected that is close to at least two study forms of transport like road, rail, waterway (canal or river), or a sea port. The least expensive method of shipping is usually by water the most expensive is by truck. Road transport is suitable use for local distribution from a central warehouse. For long distance transport especially for bulk of chemicals, rail or airway transport is suitable transport use in term of saving costs and cheaper. Besides, for at ease and cost-efficient for the movement of personnel and essential equipment and suppliers, air transports is the main transport facilities use. Gebeng industrial land is easily accessible by road via the East Coast Expressway con necting to Gebeng By-Pass and Kuantan By-Pass. It is also near the Sultan Ahmad Shah Airport, Kuantan, about 36km away and Kuantan Port about 10 km away as well as Kemaman Port, about 45 km away. Besides that, Kuantan-Kerteh Railway Linking the Kerteh Industrial Area and Kuantan Port located only to its right, makes it located more strategically.The main requirement for every plant and industry is the availability of electrical energy. It is the most important utilities to plant for every activity such as production, run of equipment or activities in the office. It supposed to have electricity with minimal impact to its adjoin and environment. Some industry generates their own electricity by their own root but in most industry and plant in Malaysia, the electricity is provided by Tenaga Nasional Berhad (TNB). The main electricity supplier in Gebeng Industrial Estate also Tenaga Nasional Berhad (TNB). The electricity supply provided by TNB for Phase I and II is supported by its 13 2/11kV main intake and for Phase III, two sources of electricity supply are available which Centralised Utility Facilities (CUF) and 12/275kV main intake. Water also one of the most important component in industry either fresh water or water utilise in equipment. The water is required for large industrial as well as general purposes, starting with water for cooling, washing, steam generation and as a raw material in the production of ethylene glycol. The water supply in Gebeng Industrial Estate is supplied from the Semambu Water Treatment Plant. The current capacity of water supply is 2MG/D. The Government of Pahang is committed in ensuring an efficient water supply in Gebeng. The steps that have been taken are by increasing the water supply to 64 MG/D, build a building of a new 200 acre dam in Sungai Lembing, Kuantan as well as build a building of new pipes and water tanks in Gebeng Industrial Estate.Last but not least, the main telecommunication supplier in Gebeng Industrial Esta te is Telekom Malaysia. They provide state of the art facilities and services such as Integrated Systems Digital Network (ISDN), digital line, MAYPAC, Internet and video conferencing. For fire fighting facilities, the Pahang Fire and Rescue segment is located near Gebeng in order to handle any emergencies. In addition, located within the vicinity of Gebeng is Petronas Centralised Emergency Facilities. Both send are equipped with HAZMAT (hazardous material) facilities. Another services provided is the Gebeng Emergency Mutual tending (GEMA), a voluntary crisis management organisation, set up from an alliance between Government agencies and private manufacturers in Gebeng. The main objective of GEMA is to execute proactive action and they also offer expert services to counter emergencies.