Factors affecting site selection & plant layout for production of Diethyl ether. Suggestion of Plant site for production in India.

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CHAPTER 6
SITE SELECTION AND PLANT LAYOUT
In this chapter factors for plant location selection and site selection also ideal location is
suggested. [15]
6.1 Factors affecting the selection of the plant location:
Proper layout includes arrangement of processing areas, and handling areas in efficient co-
ordination and with regard to such factors as:
Ø New site development or addition to previously developed
Ø site Type and quantity of the product to be produced
Ø Type of process and product control
Ø Operational convenience and accessibility
Ø Economic distribution of utilities and services like water, process steam, and power
Ø Type of building and building code requirements
Ø Health and safety considerations including possible hazards of fire, explosion and
fumes
Ø Waste disposal problems
Ø Auxiliary equipment
Ø Space available and space require
Ø Roads and rail roads
Ø Possible future expansion
Ø Sensible use of floor and elevation space
Cost of construction can be minimized by adopting a layout that gives shortest run of
connecting pipes between equipments and least amount of structural steel work, but this is not
necessarily the best option for operation and maintenance. Following care is taken:
Ø The base of column must be elevated and provided with necessary net positive suction
head to a pump.
Ø Two escape routes for operators are provided from each level in process buildings.
Ø Equipments should be located so that it can be conveniently tied with any future
expansion of process. Space must be left on pipe alloys for future needs and services.
Considering all factors, ideal plant layout for our plant is as under:

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Ø Process units and ancillary buildings are laid out to give most economical and personnel
around the site.
Ø Hazardous processes are at a safe distance from other building.
Ø Consideration for future expansion is economically justified.
Ø Minimum time is spent by personnel in travelling between buildings.
Ø Administrative offices and laboratories are at a considerable distance from places where
hazardous processes take place.
Ø Auxiliary buildings are placed on different site.
Ø Each equipment is at a distance of 2x2 m from each other.
Ø Control room is located adjacent to processing units, but potentially hazardous processes
are sited at a safer distance.
Ø Access roads are provided to each part of plant for construction operation and
maintenance.
Ø Storage tanks with hazardous materials are at least 10 m from site boundary.
Ø Utility buildings are sited with respect to most economical run of pipe to and from process
unit.
6.2 Selection of plant site:
Selection of plant site plays a very important role in the success of a chemical plant. If plant
is not located in the most economically favorable position, the competitive advantage of
process, so carefully engineered during research and development phases can be wiped out.
The following are the reasons of this plant site:
Ø Raw material sources:
The major raw material for the plant is ethanol. The location of an industry contributes
more towards the choice of a plant site than any other factor. Not only should this but
the supply of basic raw materials be controlled directly by the user.
The physical distance is not the only controlling factor in the source of raw materials,
for purchase price and buying expenses base point pricing, stock and reliability are
also determinates.
Ø Market location:
The location should be chosen if possible which has several competing rails, roads and
water ways as in order that the competition will help to maintain low rates and give

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better services. The relation of railway to market is as close that no pains should be
spared in making a careful investigation of freight rates before deciding upon a plant
location.
Ø Labor resources:
Before locating an industry in any particular locality, a careful study of the supply of
the available labors must be made. Factors to be considered in labor studies are supply,
kind, diversity, intelligence, wage scale, regulations, efficiency and cost.
Labors sometimes stay at a great distance from the site and hence what may have
appeared cheap location develops into a very expensive one because of the inefficiency
of labor and high turnover. Industrial housing, safety-first movement, welfare
institution, better sanitation, launch room etc. have all contributed to the solution of
labor problems. Skilled as well as unskilled persons are easily available.
Ø Land costs:
The price of land also plays quite important in the location. By selecting the plant in
the backward or subsidized area the price is reduced considerably. Moreover selecting
the area in backward area also helps in getting subsidies like sales tax etc. This helps
a lot in the price of finished goods and saves the money that can be used for work
capitals.
Ø Utilities (power, water, etc.):
Power for chemical industry is primarily obtained from the coal, water and oil. These
fuels supply the most flexible and economical source in as much as they provide for
the generation of the steam both processing and electricity production.
Water for industrial purpose can be obtained from one or two general sources: plant’s
own source or municipal supply. Here a large demand of water is needed, so
company’s own water source is required which is satisfied by GIDC wells.
Ø Effluent disposal:
Disposal of waste water and waste product is frequently a problem for the chemical
plant and therefore must be given serious consideration in choosing the site. Accurate
information on the quality and quantity of industrial waste is necessary to design waste
collection system.

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Ø Climate:
Excessive hot or cold climate necessitates construction of protective shelters and effect
the economic operation of the plant. Hence this factor should be examined when
picking a plant site.
Ø Taxation &legal restriction:
State and local tax rates on property, income, unemployment, insurance and similar
items vary from one location to another. Similarly, local regulation on zoning, building
codes, nuisance aspects and transportation facilities can have a major influence on the
final choice of a plant site. In fact, zoning difficulties can often be much more
important in terms of cost and time delays than many of the factors discussed in the
proceeding section.
Ø Site characteristics:
The characteristics of the land at proposed plant site should be examined carefully.
The topography of the trace of land and the soil structure must be considered, since
they may have a pronounced effect on construction costs. The cost of the land is
important. The new plant should be considered for construction at a location where
additional space for expansion is available.
Ø Community factors:
Cultural and recreational facilities like mosques, temples, libraries, schools, civic
theatres, concert associations etc. can have an effect on the location.
6.3 Plant layout:
The economic construction and efficient operation of a process depend on how well the plant
and equipment specified on the process flow sheet is laid out. The principal factors to be
considered are:
1. Economic consideration: construction and operating costs.
2. The process requirement.
3. Convenience of operation.
4. Convenience of maintenance
5. Safety.
6. Future expansion
7. Modular construction

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Fig.6.1: plant layout [15]

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Costs:
The cost of construction can be minimized by adopting a layout that gives the shortest run of
connecting pipe between equipment, and the least amount of structural steel works.
Operation:
Equipment that needs to have frequent operator attention should be located convenient to the
control room. Valves, sample points and instruments should be located at convenient positions
and heights. Sufficient working space and headroom must be provided to allow easy access
to equipments.
Safety:
Blast walls may be needed to isolate potentially hazardous equipment, and confine the effects
of an explosion. At least two escape routes for operators must be provided from each level in
process buildings.
Plant expansion:
Equipment should be located so that it can be conveniently tied in with future expansion of
the process.
Modular construction:
In recent years there has been a move to assemble sections of plant at the plant manufacturer’s
site. These modules will include the equipment, structural steel, piping and instrumentation.
The modules are then transported to the plant site, by road or sea.
General consideration:
Open, structural steelwork, building is normally used for process equipment; closed buildings
are only used for process operations that require protection from the weather.
6.4 Ideal Location: Nearby DAHEJ, Bharuch
Based on the above mention conditions, the Diethyl ether (DEE) manufacturing plant can be
located nearby Dahej, Bharuch.

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Ø There is an easy transportation of raw material because of easy availability of Railway
and Road.
Ø This location is very near to sea so cheap availability of water and shipment in
international market is also major advantage.
Ø It is industrially developed area so we can also get land by comfortable price.
Ø At this location, unskilled labors are easily available.