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Outline
Case study 3 Design of process plants “NylPro” – continuous & batch processes
- • IntroductionInput data
- Top management’s questions
Industrial Technologies 2
NylPro - NylPro Group introduction
• NylPro is an Italian chemical group with the main site located in Milanand several production plants distributed in various regions of Italy.
• Alldiffering from each other for the recipes (that is, the quantity of raw the plants produce different variants of nylon-based products,
materials each product requires).
A, Bcstf = silos materie prime= centrifuga= stoccaggio= fase di processo
>A
>^ B^ f.
f.
f.
> f.3^ f.4 f.
c
st Fig. 2.7 Esempio di impianto di processo con produzione a flusso continuo^ A, B^ f1, f2^ f3, f4, f5 Drawing^ f6 st Polymerization TowerStorageRaw Material SilosPost-condensation Tower , Cooling/Washing and Cutting LineSilos
Industrial Technologies 4
NYLPRO - Top Management’s questions
Top • Design the plants required for the nylon production Management’s Objective:
The Top Management has decided to consider the development of both the two different plant configurations:
• • continuous flow line (i.e. continuous flow production process);discontinuous flow line (i.e. batch production process).
For each line, the questions to be answered are:
• • what is the required plant dimensioning for the given demand?how much is the plan investment cost?
• how much are the operational costs?
Industrial Technologies 5
NYLPRO - input data
Product N66X N66Y 12.000 ton/year2.500 ton/year Demand Medium/Low Class High
N66K^ N66Z N66J 1.250 ton/year750 ton/year500 ton/year Medium/LowMedium/LowMedium/Low
• Regional market has a strong demand for 5 nylon typologies:
N66X, N66Y, N66Z, N66K and N66J
• Estimated annual demand for the 5 product types is split into two classes and foreseen as stable
HINT: Consider carefully which are the products to be made on each type of
plant configuration.
NYLPRO - input data Technical and economic data for the 50t line
1.000.000^ 200.000 200.000 €/unit.
Assembly Costs (% Plant Cost) - Cass 800.000^ 300.000^ 15%10%
160.000 40.000 0,18^50
5%^45
Power supplier base tariff (Euro/year) per Kw - Cepa Re-starting Costs (€/restart) - Cre
Maintenance Costs (% Plant Cost) (€/y) - Cmaint^ Electric Energy (Euro/kWh) - Cee^ Workers (Euro per worker per year) - Cw^ Raw Material Cost (€/t) - Crm
Raw Material Silos Polymerization Tower Wiredrawing, Cooling and Cutting Line Post-condensation Tower
Storage Silos Design Costs (% Plant costs) Operational Costs
Plant Subsystem Costs
Plant Utilization Rate (%)* Between 80% and 100% of nominal capacity Between 60% and 80% of nominal capacity 0,000,02 SR 1 - SR^ 0,981,000,98^1
Between 40% and 60% of nominal capacity Between 20% and 40% of nominal capacity Between 0% and 20% of nominal capacity 0,040,070,10 0,960,930,
Number of maintenance shutdown, for major preventive maintenance (per year)^ Planned maintenance shutdown time (days)^ Number of production campaigns (per year)
* Utilization Rate UR = Actual Production Capacity / Theoretical Production Capacity
Scheduling Coefficient
Opening hours (per day)
Availability^ Set-up time (to change product type / restart new campaign) (hours)
N° of daily shifts Installed Power (Kw)^ Nominal Production Capacity TPC (t/d) N° of requested workers per shift^ Plant Opening Days (per year)
NYLPRO - input data
150.000 450.000 200.000 €/unit.
Assembly Costs (% Plant Cost) - Cass 300.000^ 200.000^ 15%10%
80.000 40.000 0,18^50
Maintenance Costs (% Plant Cost) (€/y) - Cmaint^ Workers (Euro per worker per year) - Cw 5%^45
Wiredrawing, Cooling and Cutting Line^ Plant Subsystem Costs^ Raw Material Silos
Raw Material Cost (€/t) - Crm
Post-condensation Tower
Operational Costs Power supplier base tariff (Euro/year) per Kw - Cepa Re-starting Costs (€/restart) - Cre
Polymerization Tower
Electric Energy (Euro/kWh) - Cee
Storage Silos Design Costs (% Plant costs)
Technical and economic data for the 20t line 20
0,96^12671
Plant Utilization Rate (%)* Between 80% and 100% of nominal capacity Between 60% and 80% of nominal capacity Between 40% and 60% of nominal capacity 0,030,05 SR 0 1-SR 1,000,970,95^1
Between 20% and 40% of nominal capacity Between 0% and 20% of nominal capacity * Utilization Rate UR = Actual Production Capacity / Theoretical Production Capacity0,080,11 0,920,
Installed Power (Kw) N° of requested workers per shift Number of production campaigns (per year) Maintenance shutdown time (days)
Number of maintenance shutdown, for major preventive maintenance (per year)
Plant Opening Days (per year)
Scheduling coefficient
N° of daily shifts^ Nominal Production Capacity TPC (t/d)^ Opening hours (per day) Set-up time (to change product type / restart new campaign) (hours)
Availability
Industrial Technologies 10
NYLPRO - Top Management’s questions
Top • Design the plants required for the nylon production Management’s Objective:
The Top Management has decided to consider the development of both the two different plant configurations:
• • continuous flow line (i.e. continuous flow production process);discontinuous flow line (i.e. batch production process).
For each line, the questions to be answered are:
• • what is the required plant dimensioning for the given demand?how much is the plan investment cost?
• how much are the operational costs?
