Plant Layout and Design

7/29/2019 Plant Layout and Design

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PROCESS PLANTDESIGN & LAYOUT

David Harron & Jorge Rosas

Hatch Ingenieros y Consultores, Santiago, Chile


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PLANT DESIGN OBJECTIVEA Facility That:

Can be built within the project budget

Meets applicable standards & regulations

eets pro uct on goa s Has a competitive OPEX


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Traditional Design ProcessProcess Design

E ui ment Selection

EquipmentManufacturer

Owner

Plant Layout


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21st Century Design ProcessProcess Design

EquipmentManufacturer

Owner

E ui ment Selection

Plant Layout


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SITE LOCATION & CLIMATE Building type, open or enclosed

Existing installations

Ore transport distances & methods

Topography Extreme weather conditions

Isolation Construction considerations


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A BIT OF THE PASTDoes anyone remember these?


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AND TODAY


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HOW IT WAS Projects proceeded in logical order, step by step

Progress slow, little time for creativity or artistic input

New ideas or concepts rarely accepted Minimal new design

Design changes took a lot of time

Plant and equipment locations less refined Smaller, more spacious plants and lower costs

Fewer laws, rules and regulations

Most designs oversized

Repetition of errors, no time for as-builts


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AND HOW IT IS

CONSIDERATIONS AFFECTINGLA E DE A D

LAYOUT


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HSECHealthSafety

Environment

Community

An integrated, cohesive program affectingevery aspect of plant design and

operation.


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meets the needs of the present without

compromising the ability of future generations tomeet their own needs.

SUSTAINABLE DEVELOPMENT

Mining companies are intensely concerned abouttheir Environmental Footprint and we as

consultants are dedicated to assisting in

minimizing it.


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4 QUADRANT ANALYSIS


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FUTUREWATCH


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REGULATORS

& POLICY MAKERS

Client corporations

Mining industry

Governments at all levels

Standards organizations Special interest groups


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RISING COSTS

As represented by

100.00

$120.00

$140.00

$160.00

$0.00

$20.00

$40.00

$60.00

$80.00

NYMEX Crude Oil Price History

Dec. 05 to Aug. 08


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OPERATIONAL EFFICIENCY Mine-to-Mill

Design to Capacity


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MINING-METALLURGICAL

PROCESS DESIGN MODEL

Geological ModelLithology, Alteration, Mineralization and Structure

Block Cu Ore Grade Cu & Fe SulphideBlock Models

Grindability andFloatablility Tests

GeotechnicalModel

Extractable

Reserves Model

In-situReserves Model

Mine Plan

Geometallurgical Model

Concentrator PlantProduction Model

PRODUCTION PLANNINGProcessing Rate, Recovery

and Concentrate Quality


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TECHNOLOGICAL ADVANCES

2005

2002250

300

350

um)

TankCell

Conventional U-shapedEquipment is steadily getting larger and

more complex

1997

1994

1991

1982

0

50

100

150

200

1970 1975 1980 1985 1990 1995 2000 2005 2010

Year

Volume

(c


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ARBITRARY Client preferences

3rd party recommendations

Consultant experience

Project Standards Constructability

Operability Maintainability


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OUR TOOLSAutoCAD

PDS

Microstation

PlantSpace

MS EXCEL

Moly-Cop Tools


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ARTOR


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WHAT IS ART? Product of human creativity.

Creation of beautiful or significant things.

Superior skill learned by study, practice or

o servat on. Medium of expression where individual

and culture come together.

Human effort to imitate, supplement, alteror counteract the work of nature.


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Art is the application of that superior skill, asystem of principles and techniques

employed in the performance of a set ofactivities.

Art implies a personal, indefinable creativepower.


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Is Art merely its own objective?Is Art just something to be displayed and

admired?

Can Art also serve a functional purpose?

Can Art be incor orated into the desi n of

Art is subjective

everday objects?


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WHAT IS TECHNOLOGY? Practical application of knowledge

Manner of accomplishing a task usingtechnical processes, methods or knowledge.

c ent c met o an mater a use toachieve a commercial or industrial objective.


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THE APPLICATIONS


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EfficiencyPhilosophies

Owner Input

Testwork Mine Plan

Cutting Edge

Technology

EquipmentRequirements

CAPEX & OPEX

PLANT PROCESS DESIGN

Interpretation

KnowledgeExperience

Tools Personality

Creativity

Plant ProcessDesign


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PLANT LAYOUT DESIGN

Interpretation

HSEC

Sustainability

EquipmentRequirements

Rules, Regulations& Standards

CAPEX & OPEX

TechnologicalAdvances

Owner Input

ConstructabilityFlow

Optimization

Creativity

KnowledgeExperience

Plant LayoutDesign

Operability

Maintainability

Plant ProcessDesign

Plant SiteConsiderations

Tools Personality


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How are these applications different frompure applied technology?

C R E A T I V I T Y


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How do we incorporate our creativity in Plant

Process and Layout Design?

Filtering and applying a sometimes

overwhelming amount of information.

Incorporating the requirements and

Designing a process plant that suitsall of the conditions that affect it in

the best conceivable manner.

w s es o a os o n eres e par es,satisfying all while offending none.


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All Art is based on the artists technical skills,no matter how acquired or selectivelyapplied.

How do we conclude that what we produceis Art?

Those technical skills are combined withtalent & vision to achieve a final goal that

complies with the previously listeddefinitions


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Product of human creativity.

Creation of beautiful or significant things.

Superior skill learned by study, practice orobservation.

and culture come together.

Human effort to imitate, supplement, alter

or counteract the work of nature.


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THE CONCLUSION?Process Plant Design and Layout are quite

obviously applications of technologybut as weve seen, the technology is only a

certainly qualifies as

ART


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SOMETHING TO THINK ON!!Where and how do we quickly find, recruit,

train and develop a new generation ofdesigners with the required capabilities to


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Plant Layout and Design

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