The majority of projects seen by design contractors are continuous plants and consequently their design systems and practices are set up for these. Likewise the majority of design engineer training does not cover the differences between batch and continuous plant design and operation. Commonly engineers will never work on a batch plant design.

Batch plant design is more complex than continuous plant design. It requires more time than a similar size continuous plant, and there is more potential for a range of errors or omissions.

This paper has been compiled from the experience of process engineers who have designed and operated numerous batch plants during their careers. It will illustrate issues design engineers should be aware of when they are about to embark on a batch plant design. It covers tips on budget man-hours for design, schedule for design activities, design documentation, plant capacity modelling, batch plant equipment sizing, pressure relief systems, HAZOPs, control systems and operational challenges.