RISK MANAGEMENT AND DESIGN CONSIDERATION IN PROCESS INDUST~ CASE STUDY OF NASCO DETERGENTS JUS AND

MORRIS FERTILIZER M1NNA.

BY

IBRAHIM A. MAJT-: (91/2352)

DEPARTMENT OF CREMICAL ENGINEERING. " . SCHOOL OF ENGINEERING AND ENGINEERING TECHNOLOGY,

FEDERAL UNIVERsITY OF TECHNOLOGY, MiNNA.

"A-nIEISIS

SUBMITTED TO TIlE DEPARTMENT OF CHEMICAL ENGINEERING, . IN PARTIAL FULFILMENT. OF T1tt REQUIREMENTS FOR 'rtiE AWARD OF

DEGREE OF BACHELOR OF ENGINEERING (B • ENG) •

DECEMBER 1998.

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CERTIFICATION

I hereby certify that, this project report is the work of

and has never been presented anywhere in this fonn. rahim A. Maj i

....... ~ -::. .••••••••••••• • () •• 4: ••••••

••• ># ....... ali&- ••••• ·········~ Date Supervisor's Signature

................................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date H.O.D's Signature

.............. IiI •••••• e.~ ••••• ··&;·· •••••••••••••••• 5 •• II ••• •••••••• Date External Examiner's Sign

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D E DIe A T ION

This project ~ort is dedicated to JEHOVAH EL GIBBOK who

ted us up and will surely never let us down. And to my beloved

ents Mr Yohana Maji Kaningkon and Mrs. Helen Maji Kanigkon.

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AKNOWLEDGEMENT

I am ever grateful to God Almight~ for his mercies and grace over

life and my academic persuasion. the perfect support I enjoyed from

par~nts Mr and Mrs Y. Maji can not be quantified, hence I pray that

eod should give them long life.

My Head of D~partment Dr. J. O. Odigure is a man I will always

reckon with for his intellectual and'''professional instructions towards

the ralisation of my project and my design project as well. I am ever

greatful to the following people for theri help and encouragement during

my degree program: Mr and Mrs Philip Madu, Dr H.-Ir~t~;: "Halima Yusuf-", Miss

Hajaratu Jonathan, Mr and Mrs Yakubu Maji, Mr and Mrs Dauda Maji, Mr and

Mrs Reuben Maji, Mr Daniel Maji, Mr Ronald, Mr Jacob and Mr Enoch B.

My appreciation will be incomplete, without mentioning, Mr(Eng)

Kehinde Shada ~or his help during my project, likewise Mr(Eng) Bayo

Ogunkoya Mr(Eng) Ndagiman Ahmed Lawal; Mr(Eng) Isiaka Mohammed, Mr Bala

S. Dickson, Mr. Baba Mohammed (my printer and typist), and to all my

friends, brothers and well wishers to numerous to mention and finally

to all my church memBers for their spiritual support. God bless you All.

Title page

Certification

Dedication

Aknowledgement

Abstract

CHAPTER ONE

1.0 INTRODUCTION

1.1 Justification

1. 2 Limitation

1.3 Aims and Objectives

TABLE OF CONTENTS

1.4 Result or conswquences of failure

.cHAPTER TWO

2.0 LITERATURE REVIEW

2.0 Failur or Breakdown

Types of Breakduwn

Classification of failure or bre"akdown

Causes of Breakdown (of machines)

Corrosion

Corrosion Principles

Corrosion control

Designing for corrosion

Fatigue

.4.0 Wear

Designing for Wear

Bad guesses in design

Reliability

Reliability growth

Reliability tests

Consideration of risk in design

Maintenance Management and control

Role of Operations and maintenance department

Zero Breakdown

Machine condition diagnosis Technology

Maximizing Equipment Effectiveness

Equipment and siz major causes

Measuring Equipment effectiveness

Probabiity of failure

General guidelines for maintenance schedule

General maintenance budget guideline

Mekhods-o~ data gathering

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3.1.1 Data from Nasco detergent

3.1.2 Morris fertilizer

3.2 Determination of rate of ailure

Determination of reliability

Determination' of machine overall effectiveness

,cHAPTER FOUR

Date

CHAPTER FIVE

Equipment design

Problem statement

Raw material

Utilities and services

Product specification

flow sheeting

Matieral balance over the plant

Heat balance Data

Heat balance

Detailed equipment design

Costing

Safety

CHAPTER SIX

DATA ANALYSIS

Conclusion

Recommendation

References

Appendix I

Appendix II

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