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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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