Module 1; Industrial Plnat Design Aspects

Lesson 1.2: Overall Set-Up of an Industrial Plant

Module 1, Lesson 1.2: Overall Set-Up of an Industrial Plant

Lesson Summary

Industrial Plant set-up involves the overall designs necessary from Planning, Selections of Equipment’s,
Engineering design calculations, permits to operations and other requirements necessary for plant
design.. Once products are produce from the time the design of an Industrial Plant was conceived, up to
the last line of its process as seen in the finished product, then only one can say that the Engineering
Technical design used were the product of years in studies, experience in engineering and exposure on
the field of actual practice as a Mechanical Engineer.
Discussion

All the major Industrial Plants in Leyte areas for which discussions will be anchored as follows :

Industrial Plant Product

1. PASAR: Smelter Copper

2. PHILPHOS: Manufacturing Fertilizer

3. EDC: Geothermal Power

4. HISUMCO: Manufacturing Sugar

5. PSPI: Processing Paper

6. Global: Manufacturing Virgin Coconut Oil

 Industrial Plant Product
1. PASAR: Smelter Copper
2. PHILPHOS: Manufacturing Fertilizer
3. EDC: Geothermal Power
4. HISUMCO: Manufacturing Sugar
5. PSPI: Processing Paper
6. Global:
All of this Industrial Manufacturing
Plant regardless Virgin Coconut
if it is an smelter, processing Oil
or manufacturing companies, for so
long as there are equipment’s & machineries involves, and product output, then Mechanical Engineers
presence is a must. For this subject, from the above enumerated plants, we are going to discuss the
Industrial Plant for sugar manufacturing, for which this is what I’m good at considering that this is where I
gained my experience & technical knowledge in the field of actual practice as a Professional Mechanical
Engineer.

Furthermore, one major reason why I elected to use Sugar Industry for this discussion is that, Sugar Mills
has one of the most complete in terms of its equipment’s/machineries involve on different processes
areas of involvement from the fresh cane stalks down to raw ( brown ) sugar product after undergoing
processes that involves Mechanical Engineering Concepts.
Comprising a Typical Industrial Plant, Set up and Requirements.
Note:

Before starting the discussion proper, I’m going to show you an actual process video for
sugar manufacturing where I am connected at. Although, this is

confidential considering that this video is a company property, but still I do feel that
what your going to see is very essential for the progress of this discussions.
RECORDING IS STRICTLY PROHIBITED.

FILM SHOWING
SUGAR MANUFACTURING
Sugar Process are Subdivided into areas as follows:

1. 1. Boiler Power Plant

2. 2. Power House

3. 3. Mill & Cane yard

4. 4. Boiling House

5. 5. Warehouse
 Sugar Process are Subdivided into areas as follows:

1. Boiler Power Plant is where heat energy are produce for the following

reasons:

1.1 To drive the turbo generator set in the Power House to produce power.

1.2 To drive the turbines as engines for crushing the sugar canes through

its 3 mill rollers x 5 tandeems.

1.3 To evaporate the water contents of its juice from crushed canes which

are composed of 30% sucrose or sugar & 70% water. This water is

being evaporated at the process Boiling House using Evaporator

vessels.
 Sugar Process are Subdivided into areas as follows:

1. Boiler Power Plant is where heat energy are produce for the following

reasons:

1.4 To preheat the feedwater in the Deaerator prior to supplying the Boiler

Steam Generator.

1.5 To disinfect and cleaning of bacteria’s present in the Mill, Quality

Assurance Lab., etc.

1.6To dry or relieve the sugar from moisture content after processing in the sugar

dryer.

1.7 Primarily heat energy produced by the boiler power plant is very

essential, for the overall operation of an industrial plant.

 Sugar Process are Subdivided into areas as follows:

2. Power House, is where power generation occurs through the two (2) turbo generator set at a combined
11 megawatts power to drive large motors that LEYECO cooprative power cannot do, through its
transformers and control systems.

3. The Mill, receives the sugar canes from the fields wherein it is being crushed to produce juice, through its 5

mill tandems @ 3 mill rollers per mill tandem. The juice that are extracted are being pumped to the process

Boiling House to evaporate its water. The cane fiber are conveyed to the Boiler Power Plant as fuel for the

furnace during combustion to produce flue gas the during steam heat energy productions.

4. Process Boiling House, evaporates the 70% water from its juice through it evaporators until pure sucrose

are attained as one of the major material for sugar processing in the vacuum pans.
5. Warehouse, receives the finished product which is the raw or brown sugar where it is being stored in
bags and in bulk for either refining to white sugar or sold in bags as raw sugar
 Note:

1. All of the above major areas in the sugar processing requires major mechanical equipments,
maintained and manage by Mechanical Engineers.
2. Industrial Plant Design are one of the most complex and broad Engineering designs in the field of
actual practice in Mechanical Engineering. From the time the concept design was conceived,
meticulous planning, calculations until its constructions, installation from different fields of
Engineering that should be simultaneously done & properly supervised until its completions,
makes it very tedious.
3. Commissioning follows after the completions of the design project. Every aspects of the design
should work simultaneously until finish product are achieved. Mechanical Engineers normally leads
the charge during the realization of the Industrial Plant Design.
For a Sugar Manufacturing Industrial Plant, selections of major & minor equipments, machineries,
instruments, auxiliaries, etc. are carefully selected based on its specifications & standards.
Engineering designs, of the above mentioned must all be in placed prior to any start of work. Even
during operations & productions, the responsibility of the Mechanical Engineer does not end there,
Government permits and compliance must also be in place in accordance with the laws of the
Philippine Government for the continuity of its operations.

Below are enumerated partial design considerations that we are going to discuss for the
durations of this subject matter as follows:

1. Power sources (Main Power, Back-up Power & Coop. Power)

2. Selection of equipments & machineries such as pumps.

3. Plant Layout

4. Proper storage & Handling

5. Government compliance & permits to operate.

Below are the illustrations of selected topics that we are going to discuss for this semester. As broad as
the Industrial Plant subject is, if we are going to discuss everything on it, we will not be able to finish the
discussion even in 5 years’ time, since it will take experience and exposure to do so. Selected topics that
are essentials for Industrial Plant Design shall only be discussed on this subject per stated below under
the Industrial Plant Structure.
End of Module 1, Lesson 1.2