Facility siting and plant layout optimization for chemical process safety

Designing the process layout in a chemical plant is a complex and multidisciplinary task requiring input from experts in fields such as chemical, civil, mechanical, and instrument engineering. Plant layout entails the allocation of a given number of facilities on a given piece of land. Determining the optimal distribution of facilities in a plant requires an optimization calculation, including a variety of distance constraints, one of which is related to process safety. A few approaches have been taken to transform consequence analysis, such as toxic gas dispersion and its mitigation as well as the risks of fire and explosions, into mathematical equations as constraints of an optimization problem. An optimization problem with constraints related to safety is not easy to solve given limitations such as nonlinearity, uncertainty, and ethical difficulties in converting human life to costs for calculation purposes. However, safety concerns have increased to the point that developing this type of approach is necessary. The objective of this study was to review the current methodologies for plant layout optimization and to resolve facility siting issues. Process safety concepts are considered with a view to identifying gaps and issues with current methods in order to develop better methodologies for designing safer layouts.

[1]  Il Moon,et al.  Integration of qualitative and quantitative risk assessment methods for gas refinery plants , 2013, Korean Journal of Chemical Engineering.

[2]  Kyu-Yeul Lee,et al.  Optimal liquefaction process cycle considering simplicity and efficiency for LNG FPSO at FEED stage , 2014, Comput. Chem. Eng..

[3]  Dongil Shin,et al.  Design and implementation of an integrated safety management system for compressed natural gas stations using ubiquitous sensor network , 2014, Korean Journal of Chemical Engineering.

[4]  Michael Lederhose,et al.  An Approach to Plant Layout Optimization , 1999 .

[5]  M. Sam Mannan,et al.  A model to optimize facility layouts with toxic releases and mitigation systems , 2013, Comput. Chem. Eng..

[6]  Michael C. Georgiadis,et al.  A general mathematical programming approach for process plant layout , 1999 .

[7]  M. R. Wilhelm,et al.  A layout design heuristic employing the theory of fuzzy sets , 1987 .

[8]  Matthew J. Realff,et al.  Geographic and process information for chemical plant layout problems , 1999 .

[9]  Panos M. Pardalos,et al.  Simulated Annealing and Genetic Algorithms for the Facility Layout Problem: A Survey , 1997, Comput. Optim. Appl..

[10]  Lazaros G. Papageorgiou,et al.  Continuous-Domain Mathematical Models for Optimal Process Plant Layout , 1998 .

[11]  Leon F. McGinnis,et al.  Facility Layout and Location: An Analytical Approach , 1991 .

[12]  Dongil Shin,et al.  Optimal multi-floor plant layout with consideration of safety distance based on mathematical programming and modified consequence analysis , 2011 .

[13]  René Bañares-Alcántara,et al.  Optimisation of process plant layout using genetic algorithms , 1998 .

[14]  Henri Pierreval,et al.  Facility layout problems: A survey , 2007, Annu. Rev. Control..

[15]  Frank Pearson Lees,et al.  Loss prevention in the process industries : hazard identification, assessment, and control , 1980 .

[16]  Lazaros G. Papageorgiou,et al.  Efficient solution approaches for the multifloor process plant layout problem , 2003 .

[17]  Rakesh Nagi,et al.  Finite-Size Facility Placement in the Presence of Barriers to Rectilinear Travel , 2002, Oper. Res..

[18]  G. Reklaitis,et al.  Chemical plant layout via graph partitioning-1. Single level , 1994 .

[19]  T. Koopmans,et al.  Assignment Problems and the Location of Economic Activities , 1957 .

[20]  Michael Lederhose,et al.  CAPD - computer-aided plant design , 2004, Comput. Chem. Eng..

[21]  Teofilo F. Gonzalez,et al.  P-Complete Approximation Problems , 1976, J. ACM.

[22]  M. Sam Mannan,et al.  A stochastic approach for risk analysis in vapor cloud explosion , 2015 .

[23]  G. Froment,et al.  Kinetic Modeling of Coke Formation and Deactivation in the Catalytic Cracking of Vacuum Gas Oil , 2003 .

[24]  Rakesh Nagi,et al.  Contour line construction for a new rectangular facility in an existing layout with rectangular departments , 2004, Eur. J. Oper. Res..

[25]  Carl D. Laird,et al.  A new approach for facility siting using mapping risks on a plant grid area and optimization , 2010 .

[26]  Kam-Fai Wong,et al.  FACOPT: a user friendly FACility layout OPTimization system , 2003, Comput. Oper. Res..

[27]  Lazaros G. Papageorgiou,et al.  A Construction-Based Approach to Process Plant Layout Using Mixed-Integer Optimization , 2007 .

[28]  Alexander Shapiro,et al.  The Sample Average Approximation Method Applied to Stochastic Routing Problems: A Computational Study , 2003, Comput. Optim. Appl..

[29]  J. W. Giffin,et al.  The Vertex Splitting Algorithm for facilities layout , 1997 .

[30]  Junbin Gao,et al.  A new algorithm for removing node overlapping in graph visualization , 2007, Inf. Sci..

[31]  Dedy Ng,et al.  An approach for risk reduction (methodology) based on optimizing the facility layout and siting in toxic gas release scenarios , 2010 .

[32]  M. Sam Mannan,et al.  A Comparison of Deterministic and Stochastic Approaches to Solve the Facility Layout Problem with Toxic Releases , 2009 .

[33]  Michael C. Georgiadis,et al.  Layout of process plants: A novel approach , 1997 .

[34]  Lazaros G. Papageorgiou,et al.  An MILP Approach to Safe Process Plant Layout , 2004 .

[35]  Dedy Ng,et al.  New Approach To Optimizing the Facility Siting and Layout for Fire and Explosion Scenarios , 2011 .

[36]  Marc Goetschalckx,et al.  An interactive layout heuristic based on hexagonal adjacency graphs , 1992 .

[37]  Stefanie Seiler,et al.  Facility Layout And Location An Analytical Approach , 2016 .

[38]  S. Heragu,et al.  Efficient models for the facility layout problem , 1991 .

[39]  Richard Gordon Newell.  Algorithms for the design of chemical plant layout and pipe routing , 1975 .

[40]  Lazaros G. Papageorgiou,et al.  Process plant layout using an improvement-type algorithm , 2009 .

[41]  Nilay Shah,et al.  Simultaneous design, layout and scheduling of pipeless batch plants , 1996 .

[42]  Meir J. Rosenblatt,et al.  The facilities layout problem: a multi-goal approach , 1979 .

[43]  Ignacio E. Grossmann,et al.  A mathematical programming model for optimal layout considering quantitative risk analysis , 2014, Comput. Chem. Eng..

[44]  Lazaros G. Papageorgiou,et al.  Optimal multi-floor process plant layout , 2002 .

[45]  Mark Kaszniak,et al.  Lessons after Bhopal: CSB a catalyst for change , 2005 .

[46]  Behdad Moghtaderi,et al.  Journal of Loss Prevention in the Process Industries , 2016 .

[47]  Andreas Bortfeldt,et al.  A genetic algorithm for the two-dimensional strip packing problem with rectangular pieces , 2006, Eur. J. Oper. Res..

[48]  Elwood S. Buffa,et al.  A Heuristic Algorithm and Simulation Approach to Relative Location of Facilities , 1963 .

[49]  A. R. Ciric,et al.  An MINLP Approach for Safe Process Plant Layout , 1996 .

[50]  Pyung Jae Park,et al.  Study of Multi Floor Plant Layout Optimization Based on Particle Swarm Optimization , 2014 .

[51]  Alan R. McKendall,et al.  Simulated annealing heuristics for the dynamic facility layout problem , 2006, Comput. Oper. Res..

[52]  T. A. Lacksonen.  Preprocessing for static and dynamic facility layout problems , 1997 .

[53]  William Johns,et al.  Computer‐Aided Chemical Engineering , 2011 .

[54]  Ana Paula Barbosa-Póvoa,et al.  Optimal design and layout of industrial facilities: An application to multipurpose batch plants , 2002 .

[55]  Hanif D. Sherali,et al.  Enhanced Model Formulations for Optimal Facility Layout , 2003, Oper. Res..

[56]  Sue Abdinnour-Helm,et al.  Tabu search based heuristics for multi-floor facility layout , 2000 .

[57]  J. Martens.  Two genetic algorithms to solve a layout problem in the fashion industry , 2004, Eur. J. Oper. Res..

[58]  Thomas A. Lacksonen,et al.  Static and Dynamic Layout Problems with Varying Areas , 1994 .

[59]  Benoit Montreuil,et al.  A Modelling Framework for Integrating Layout Design and flow Network Design , 1991 .

[60]  M. Sam Mannan,et al.  An approach to solve the facility layout problem based on the worst-case scenario , 2010, Journal of Loss Prevention in the Process Industries.

[61]  Ross E. Swaney,et al.  Optimization of process plant layout with pipe routing , 2005, Comput. Chem. Eng..

[62]  Nicos Christofides,et al.  Contributions to the quadratic assignment problem , 1980 .

[63]  Mário Mestria,et al.  Metaheuristic methods for a class of the facility layout problem , 2000, J. Intell. Manuf..

[64]  M. Sam Mannan,et al.  A MINLP approach for layout designs based on the domino hazard index , 2014 .

[65]  R. J. Walter,et al.  Center for Chemical Process Safety of the American Institute of Chemical Engineers , 2010 .

[66]  Lazaros G. Papageorgiou,et al.  A MILP model for N-dimensional allocation , 2007, Comput. Chem. Eng..

[67]  Kurt Ernst Weil.  Plant layout and design , 1967 .

[68]  Timothy L. Urban.  A multiple criteria model for the facilities layout problem , 1987 .

[69]  Ana Paula Barbosa-Póvoa,et al.  Optimal 3D layout of industrial facilities , 2002 .

[70]  Dongil Shin,et al.  Risk Index Approach for the Optimal Layout of Chemical Processes Minimizing Risk to Humans , 2013 .

[71]  André R. S. Amaral.  On the exact solution of a facility layout problem , 2006, Eur. J. Oper. Res..

[72]  Chun Hung Cheng,et al.  A Note on "A Hybrid Genetic Algorithm for the Dynamic Plant Layout Problem" , 2006 .

[73]  M. Sam Mannan,et al.  Optimal facility layout under toxic release in process facilities: A stochastic approach , 2010, Comput. Chem. Eng..

[74]  Gintaras V. Reklaitis,et al.  Chemical plant layout via graph partitioning—II. Multiple levels , 1996 .

[75]  M. Sam Mannan,et al.  A simplified steady-state model for air, water and steam curtains , 2012 .

[76]  Yunfeng Wang,et al.  A genetic algorithm for cellular manufacturing design and layout , 2007, Eur. J. Oper. Res..