Chemical Process Industries Ch.E-203

Umair Aslam Assistant Professor

Department of Chemical Engineering

umairaslam6822@gmail.com

Process

Movement of data or material towards a known goal or end result, by passing it through a series of stages or a sequence of actions.

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Sections Of A Chemical Plant

• Process

• Utility

• Safety

• Maintenance

• Ware House

• Research and Development

• Quality and Control Laboratories

• Administration Depratment of Chemical Engineering 3

Course Outline

• Introduction to process flow sheeting, process flow diagrams, standard symbols

• Detailed study of the following group of industries:

– Water treatment

– Acid industries

• Hydrochloric acid

• Sulphuric acid

• Nitric acid

• Phosphoric acid

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– Alkali industries

• Soda Ash

• Caustic Soda

• Ammonia

– Fertilizer (NPK based fertilizers)

– Cement industry

– Explosives

– Sugar industry

– Pulp and Paper industry

– Oil and Ghee industry

– Glass and Ceramics industry

– Soap and Detergent

– Insecticides and Surface coating industries

– Petro-chemicals Depratment of Chemical Engineering 5

Books

• Shreve’s Chemical Process Industries,5th Or 6th Edition, George T. Austin

• Introduction To Chemical Processes (Principles, Analysis And Synthesis), International Edition, Regina M. Murphy

• A Text Book Of Chemical Technology, G. N. Pandey, Volume I

• Chemical Engineering, D. Kuznetsov

• Hawley's Condensed Chemical Dictionary

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• State

– States of matter

– Steady state

– Uniform state

• Phase

• Temperature

• Pressure

• Heat

• Flow

• Equipment/Apparatus/Instruments

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• Reaction

– Physical

– Chemical

• Separation/Purification

• Heat Exchange

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Chemical Process Diagrams

• The most effective way of communicating information about a process is through the use of flow diagrams.

• Flow Diagrams – Block Flow Diagrams (BFD)

– Process Flow Diagrams (PFD) – Piping and Instrument Diagrams (P&ID) – often referred to

as Mechanical Flow Diagram Complexity Conceptual increases understanding increases As chemical engineers, we are most familiar with BFD and

PFD.

The Block Flow Diagram (BFD)

• BFD shows overall processing picture of a chemical complex

– Flow of raw materials and products may be included on a BFD

– BFD is a superficial view of facility

The Block Flow Diagram (BFD)

• Emphasis is not on details regarding blocks; focus on flow of streams through process.

• Conventions: – Operations shown by blocks

– Major flow lines shown with arrows giving flow direction

– Flow goes from left to right whenever possible

– Light streams toward top, heavy streams toward bottom

– Critical information unique to the process supplied (i.e., reaction stoichiometry, conversion)

– Avoid crossing lines; horizontal continuous, vertical broken.

– Simplified material balance (overall)

The Block Flow Diagram (BFD)

The Block Flow Plant Diagram

The Process Flow Diagram (PFD)

• PFD shows all process engineering information

• Typical conventions (vary by company): – All major equipment represented, uniquely numbered

– All process flow streams shown and uniquely numbered, with description of thermodynamic conditions and composition (often in an accompanying table)

– All utility streams supplied to major process equipment shown

– Basic control loops, illustrating control strategy during normal operation

Process Flow Diagram (cont’d)

Process Flow Diagram (cont’d)

The Process Flow Diagram (cont’d)

Essential Information

Stream Number

Temperature (°C)

Pressure (bar)

Vapor Fraction

Total Mass Flow Rate (kg/h)

Total Mole Flow Rate (kmol/h)

Individual Component Flow Rates (kmol/h)

Optional Information

Component Mole Fractions

Component Mass Fractions

Individual Component Flow Rates (kg/h)

Volumetric Flow Rates (m3/h)

Significant Physical Properties

Density

Viscosity

Other

Thermodynamic Data

Heat Capacity

Stream Enthalpy

K-values

Stream Name

Piping & Instrument Diagram

• Piping & Instrument Diagram (P&ID) – Construction Bible

• Contains: plant construction information (piping, process, instrumentation)

• support documents of the PFD used for planning for plant construction and maintaining the plant thereafter

• Each PFD requires many P&IDs to provide the necessary data • Used as a checklist at the final walk-through prior to start up to

assure each detail has been attended to • Use by/to

– MEs and CEs to build/install equipment – Instrument engineers to specify/install/check control systems – Piping engineers to develop plant layout and elevation drawings – Project engineers to develop plant and construction schedules

Piping & Instrument Diagram

Stream Numbering & Drawing

• Number streams left to right when possible

• Horizontal lines are dominant

yes no no

Stream Information - Flags

Stream Drawing

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