CHEMICAL PLANT DESIGN

Chapter 1

Dr. Muhammad Rizwan

Assistant Professor
NFC-IET
HOW DOES PROCESS DESIGN EVOLVE:
 Design problems are always under-defined

 Missing information is obtained by making guesses or make use of thumb rule

 Various process variables give rise to large number of process alternatives

Choice of best process alternative:

 Capital and operating cost

 Environmentally friendly

 Less hazardous chemicals/conditions

 Easy to start up and operate

Not all alternatives can satisfy all criteria, therefore we shortlist few best alternatives

Approach of design engineer: the problem is always open ended

DESIGN PROJECT PROCEDURE:
The development of a design project always starts with an initial idea or plan. This initial idea
must be stated as clearly and concisely as possible in order to define the scope of the project.
General specifications and chemical engineering data should be presented along with the initial
data.

Types of Design:
The method for carrying out a design project may be divided into the following classifications,
depending on the accuracy and detail required:
1. Preliminary or quick-estimate designs

2. Detailed-estimate designs

3. Firm process designs or detailed designs

Preliminary Design: These are used as basis for determining whether further work should be
done on the proposed process.

Preliminary design is:

 Based on approximate process method
 Time spent on calculations is minimum
 Rough cast estimates are prepared
 A few details are included
DESIGN PROJECT PROCEDURE:
Detailed-estimate Design: If preliminary design is positive then detailed-estimate design may
be developed.

In detailed-estimate design:
 Cost and profit potential of an established process is determined by detailed analysis and calculations
 Drafting – room wok is minimized
 Exact specifications are not given for the equipment

Firm Process Design: When detailed-estimate design indicates that the proposed project should
be a commercial success then firm process design may be developed.

In firm process design:

 Complete specifications are presented for all components of plant

 Accurate costs based on quoted prices are obtained

 Blue prints and sufficient information to permit immediate development of the final plans for constructing
the plant
DESIGN PROJECT PROCEDURE:
Example: Hydrodealkylation of Toluene:

Toluene + H2  Benzene + CH4

2 Benzene Diphenyl + H2

Vapor phase process, Pressure = 500 Psia

Optimum temperature range: 1150 oF – 1300 oF

Limiting reactant – Toluene

To force complete conversion of toluene, excess hydrogen is used

DESIGN PROJECT PROCEDURE:
Example: Hydrodealkylation of Toluene:
DESIGN PROJECT PROCEDURE:
Example: Hydrodealkylation of Toluene:

Liquid
recycle
Benzene
product
H2, CH4
Purge

compressor
Gas
Diphenyl
recycle

furnace Reactor Flash

hh
CW

H2, feed
FIGURE 1.2-2
Hydrodealkylation of toluene; maximum energy recovery.

ENERGY INTEGRATION
DESIGN PROJECT PROCEDURE:
Example: Hydrodealkylation of Toluene:
 Reactor effluent comprises of benzene, diphenyl, unreacted toluene, hydrogen and
methane
H2, CH4 Benzene

Feed
(1) Toluene
(recycle)

Diphenyl
H2
CH4 Benzene Toluene
(recycle)

(2)

Diphenyl

ALTERNATIVES OF DISTILLATION TRAIN

DESIGN PROJECT PROCEDURE:
Example: Hydrodealkylation of Toluene:
ALTERNATIVES OF VAPOR RECOVERY SYSTEM
 Gas stream from the flash drum comprises of hydrogen, methane, benzene and toluene

 Vapor recovery system is design to treat the gas stream before vent to atmosphere (or
integration with the remainder of process)

 Options for vapors recovery:

(1) Condensation;
(2) Absorption;
(3) Adsorption;
(4) Membrane.
 Is a vapor recovery system needed? What is the economics of vapor recovery?
DESIGN PROJECT PROCEDURE:
Example: Hydrodealkylation of Toluene:

Vapor recovery Purge

system H2 , CH4

H2 , CH4
Reactor Phase
system split
Toluene

Benzene
Liquid separation
system
Dipheny1

Simplified Flowsheet for the Separation System

 Example: Hydrodealkylation of Toluene:
 Recycle streams are associated with significant costs
 Cost involved for separation
 Costs involved for recycle

 Gas recycle is more cost intensive as it requires compressor which has high capital and
operational cost
Gas Purge
recycle H2 , CH4

Benzene
H2 , CH4 Reactor Separation
Toluene system system
Dipheny1

Toluene
recycle
Recycle Structure of the Flowsheet
Example: Hydrodealkylation of Toluene:
Purge
H2 , CH4

H2 , CH4 Benzene
Process
Toluene Dipheny1

Input-Output Structure of the Flowsheet

 Simplest possible flowsheet
 Assess economic potential of the process
 Cost of raw material
 Cost of the product

 Difference gives the VALUE ADDITION

SYSTEMATIC APPROACH FOR PROCESS DESIGN:
 Assessment of economic potential at each step

 Alternatives of process design

Hierarchy of decisions
1. Batch versus continuous
2. Input-output structure of the flowsheet
3. Recycle structure of the flowsheet
4. General structure of the separation system
a. Vapor recovery system
b. Liquid recovery system
5. Heat-exchanger network
 FEASIBILITY SURVEY:
Before any detailed work is done on the design, the technical and economic factors of the proposed process
should be examined.

Following is a list of items that should be considered in making a feasibility survey:

1. Raw materials (Availability, quantity, quality, cost)

2. Thermodynamics and kinetics of chemical reactions involved (equilibrium, yields, rates, optimum conditions)

3. Facilities and equipment available at present

4. Facilities and equipment which must be purchased

5. Estimation of production costs and total investment

6. Profits (probable and optimum, per pound of product and per year, return on investment)

7. Materials of construction

8. Safety consideration

9. Markets (present and future supply and demand, present uses, new uses, present buying habits, price range for products and by
products, location, and number of possible customers)

10. Competition (overall production statistics, comparison of various manufacturing processes, product specifications of
competitors)

11. Properties of products (chemical and physical properties, specifications, impurities, effects of storage)

12. Sales and sales service (method of selling and distributing, advertising required, technical services required)

13. Shipping restrictions and containers

14. Plant location

15. Patent situation and legal restrictions

FLOW DIAGRAMS:
The chemical engineer uses flow diagrams to show the sequence of equipment and unit operations in
the overall process. Flow diagrams are to:
1. Simplify visualization of the manufacturing procedure
2. Indicate the quantities of material and energy transfer.

There are three types of flow diagrams:

1) Qualitative

2) Quantitative

3) Combined-detail

Qualitative Flow Diagrams:

 Flow of materials

 Unit operations involved

 Special information on operating temperature and pressure

Qualitative Flow Diagrams:
Quantitative Flow
Diagrams:

A quantitative flow
diagram shows the
quantities of materials
required for the process
operation.
Combined-detail Flow Diagrams:
 Location of temperature and pressure regulators and indicators

 Location of critical control valves and special instruments

 Each piece of equipment is shown and is designated by a defined code number

 For each piece of equipment specification are given

COMPARISON OF DIFFERENT PROCESSES:
In a course of design project it is necessary to determine the most suitable process for obtaining
a desired product. Various processes must be compared in order to select the one best suited for
the existing conditions.

The following factors should be considered:

Technical Factors:
 Process flexibility

 Continuous operation

 Special controls involved

 Commercial yields

 Technical difficulties involved

 Energy requirement

 Special auxiliaries required

 Possibility of future development

 Health and safety hazardous involved

COMPARISON OF DIFFERENT PROCESSES:
Raw Materials:
 Present and future availability

 Processing required

 Storage requirements

 Materials handling problems

Waste Products and By-Products:

 Amount Produced
 Value
 Potential Markets and Uses
 Manner of discard
 Environmental aspects

Equipment:
 Availability

 Materials of construction

 Initial cost

 Maintenance and installation costs

 Replacement requirements

 Special designs
COMPARISON OF DIFFERENT PROCESSES:
Plant Location:
 Amount of land required
 Transportation facilities
 Proximity to markets and raw-material sources
 Availability of service and power facilities
 Availability of labor
 Climate
 Legal restrictions and taxes

Costs:
 Raw materials

 Energy

 Depreciation

 Other fixed charges

 Processing and overhead

 Special labor requirements

 Real estate

 Patent rights

 Environmental controls
COMPARISON OF DIFFERENT PROCESSES:
Time Factor:
 Project completion deadline

 Process development required

 Market timeliness

 Value of money

Process Considerations:
 Technology availability

 Raw materials common with other processes

 Consistency of product within company

 General company objectives