Module I PEE

Affiliated to VTU, Belagavi,
Approved by AICTE, New Delhi,

Recognized by UGC with 2(f) & 12(B)
Accredited by NBA & NAAC
Process Engineering Economics

MVJ19CH742
Module - I
Prepared By: Dr. Augusta Pachathu

Assistant Professor
Department of Chemical Engineering
Affiliated to VTU, Belagavi, Approved by AICTE, New Delhi, Recognised by UGC with 2(f) & 12 (B), Accredited by NBA & NAAC 1
An Autonomous Institute
MODULE 1: Process Design Development
▪ Overall planning of a plant

▪ Feasibility studies
▪ Material & energy balance
▪ Equipment sizing and selection
▪ Analysis of Process flow sheet
▪ P & I diagram
▪ Plant layout and location
▪ Factors affecting plant design
Introduction
Chemical engineers need the Knowledge of basic science and related engineering concept
(thermodynamics, heat and mass transfer)
Knowledge Apply Develop
▪ Chemical engineers’ prime role is to design, construct and operate chemical plants
▪ Gather additional information from papers or existing plant and act as a consultant or advisor
▪ Capable to identify secured sufficient usable data which are reliable
▪ Willing to consider new design, understand controlling factors (physical or chemical) and
improve techniques
Classes of chemical products
Chemical products Produced: Large volume, Eg sulfuric acid, nitrogen,

Commodity or bulk
Purchase : chemical oxygen, ethylene and
chemicals
composition, purity and price chlorine
Produced: Large volume, n-butyric acid, barium

Fine chemicals Purchase : chemical
titanate powder
composition, purity and price
pharmaceuticals, pesticides,
Specialty or effect or
Purchase : effect of function dyestuffs, perfumes and
functional chemicals
flavourings
Process Design Development
Innovative approach (new or existing plant) - profitable,
controlled, operational safety and environmentally sound
▪ Development of design database

✓ Literature study
✓ Patent search
▪ Process creation
✓ Batch Vs Continuous operation
✓ Raw material and product specification
✓ Process synthesis step
▪ Process design
Development of design database
Define the Recognize Identify the
scope Design problem data
• Latest design, flowsheet, equipment and simulation

Literature Survey • Stanford Research Institute – documents on process
• ASPEN PLUS, HYSYS, CHEM CAD, PRO – II
• Expired patent provide information

Patent Search • Available in library and internet
Process creation
Involves synthesis of various configuration of processing operation – product in a
reliable, safe and economic with high yield and minimum by-product or waste
Past
Experience Changed
Use of heuristics/ quantitative and
thumb rule scientific (decision
tree analysis and
mathematical
programming aid)
Recently
✓ Batch Vs Continuous operation
▪ Continuous – preferred for commodity products- reduced labour cost,
improved process control, uniform product quality
▪ Batch/ semi batch- small production or speciality products
▪ Prime interest is flow rate required for the product
▪ Then composition, phase, form (particle size and distribution),
temperature, pressure and product stream
✓ Process synthesis step
Synthesis step Basic processing operation
Molecular change Chemical reaction
Composition change Separation of mixture
Phase elimination Phase separation
Temp/ pressure/ phase difference Change in Temp/ pressure/ phase
Distribution change Mixing of stream
Arrangement of process involves degree of conversion, reaction rate, competing side

reaction, existence of reversible reaction
Reaction – at what temp, pressure carried out, methods to add / remove energy during
reaction, choice of catalyst
Process design
Process must be compared to select the suitable design
1. Technical factors a. Process flexibility b. Continuous operation c. Special

controls involved d. Commercial yields e. Technical difficulties involved f. Energy
requirements g. Special auxiliaries required h. Possibility of future developments i.
Health and safety hazards involved
2. Raw materials a. Present and future availability b. Processing required c.

Storage requirements d. Materials handling problems
3. Waste products and by-products a. Amount produced b. Value c. Potential

markets and uses d. Manner of discard e. Environmental aspects
4. Equipment a. Availability b. Materials of construction c. Initial costs d.
Maintenance and installation costs e. Replacement requirements f. Special
designs
5. Plant location a. Amount of land required b. Transportation facilities c.

Proximity to markets and raw-material sources d. Availability of service and
power facilities e. Availability of labor f. Climate g. Legal restrictions and
taxes
6. Costs a. Raw materials b. Energy c. Depreciation d. Other fixed charges e.

Processing and overhead f. Special labor requirements g. Real estate h. Patent
rights i. Environmental controls
7. Time factor a. Project completion deadline b. Process development required c. Market
timeliness d. Value of money
8. Process considerations a. Technology availability b. Raw materials common with other

processes c. Consistency of product within company d. General company objectives
▪ Pilot plant/semi work scale desirable for accurate design
▪ Valuable information – material and energy balance, process condition, yield, rate and
grade of raw material and product, MOC, other pertinent design variables.
Types of process design
Method for carry out the design may be divided
1. Order of magnitude design

2. Study or factored design
3. Preliminary design
4. Detailed – estimate design
5. Final process design
First two- used to determine the level of investment required
Preliminary design: Based on the process methods and rough cost
estimations are prepared with few details and minimum time spent on
calculation
✓ Utilize flow sheet developed in process creation
✓ Establish workable manufacturing process
✓ After method development comparison of design need to be made
Columns - No. of plates, operation condition, column diameter, MOC
Vessels – size, holdup time, MOC, packing/ baffles
Reactors – catalyst type and size, bed dia and thickness, heat transfer
configuration, cycle and regeneration, MOC
Heat exchanger and furnace- log mean- temp difference, vapourized percent,
pressure drop desired, MOC
Pumps and compressors - type, power requirement, pressure difference,

viscosities, working pressure
▪ Selection of material is connected with the design and equipment
▪ Utility need- utilities and labour requirement
▪ Capital investment and total product cost
Preparation
of flow
Bases for Utilities and Capital
diagram (flow Selection of
design labour investment
rate and equipment
(controlled) requirement and total cost
stream
condition)
Detailed – estimate design
Further work is justified then detailed estimate design may be developed where cost and profit
potential are determined by detailed analysis and calculation, piping and layout is minimize
✓ Manufacturing process
✓ material and energy balances
✓ process conditions on temperature and pressure variation
✓ yields, reaction rates and time cycle
✓ material of construction
✓ Utilities requirement
✓ Plant site
Final process design: Final step is the blueprint with sufficient information to
execute the construction (specification, cost based on quote)
▪ Purchase standard equipment and material for construction
▪ Piping diagram included
▪ Specification for warehouses, labs, guard houses fencing, change houses and
transportation facilities
▪ Safety condition and environment impact
Feasibility studies
▪ Detailed work should be done on the process design and the technical and economic factors
examined
▪ Various reaction and physical processes involved must be consider along with potential market
condition for the product
▪ Preliminary survey gives probable success of the project
Following list of items to be consider for the 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 considerations
9. Markets (present and future supply and demand, present uses, new uses, present buying habits,
price range for products and by-products, character, 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
Types of process
✓ Batch (transient)
✓ Continuous (steady state)
✓ Semi batch
Steps involved in material balance
1. Draw and label block diagram
2. Select basis based on require data
3. Select system boundaries and start material balance from OMB followed by individual
balance of components
4. Solved the problem from formed equation
1. An aqueous solution of sodium hydroxide contains 20%. It is desire to produce 8% of
NaOH by diluting it with pure stream. Determine the feed rate of 20% of NaOH and stream
to produce 2300 kg/min of 8% of NaOH.
2. 1 Kg/hr of the mixture of benzene and toluene containing 50% of benzene by mass is
separated by distillation into two fraction. The mass flow rate of benzene in the top stream
is 450 kg/ B/h and that of toluene in the bottom stream is 475 kg T/h. The operation is at
steady state. What are the distillate and bottom flow rate?
Material Balance
to determine the
over the complete quantities of raw
process material required and
production rate
Material balance
over individual process to set theprocess

unit stream and composition
Material balance is also useful tool for the following:

1. The study of the plant operation & troubleshooting.
2. Check performance against design.
3. Check the instrument calibration.
Direct application of law of conservation of mass to design process
mass in = mass out
Mass can neither be created nor destroy but can be transform from one form to other form
General balance equation
In + generation- Out - consumption = Accumulation
Steady state accumulation =0
Without chemical reaction input = output
Unsteady state accumulation = constant
non
reactive Incomplete
system Combustion
reactive Complete
Mass balance problem
▪ Direct method - few stream and unknown variables can be solved
▪ Algebraic method – several stream and complex problem
▪ Commercial software – for steady state: Aspen plus, CHEMCAD
steady state and dynamic: HYSYS, PRO/II and DYNSIM, UniSim Design
Limiting Reactant:
• The amount of reactant consumed or product formed - reaction proceeded to
completion.
• Reactants must be fed in stoichiometric proportion to the limiting reactant
• The component disappear towards end of the reaction is called rate determining
component (concentration determines the reaction rate)
Stoichometry:
• Depend on the balance chemical reaction equations.
• Not all the reactions goes to completion (review based on the yield, incomplete
reaction)
• Not all reactants are consumed
Tie Component:
• The component passes unchanged through a process unit (inert component)- tie component
• The total amount of input & output can be calculated if their compositions are known.
Bypass:
• A flow stream may be divided and some part diverted (bypassed) around some units.
• This procedure is used to control stream composition or temperature.
Recycle:
• Unused raw materials emerging from a process unit enters back to the feed.
• Overall system balances are convenient for analyzing process with recycle.
Purge:
• A stream that's withdrawn from a process is completely recycled.
• If the species weren't removed in the purge, it would accumulate in the process system and
eventually lead to shutdown.
Purge stream used to:
• Maintain the steady state conditions in the system
• Prevent the accumulation of inert or undesired materials
Theoretical amount (ntheo)- maximum product produce from the reactant or maximum amount of reactant
consumed
Eg
What is the theoretical amount of ammonia produced by reacting 28 g of N2 and 8 g of H2?
Excess:
A reagent may be supplied in excess to promote the desired reaction to:
1- Maximize the use of an expensive reagent.
2- Ensure complete reaction of a reagent, as in combustion.
Fractional Conversion:
• Ratio of amount reacted to amount fed.
• The fractional conversions of different reactants are generally different unless the reactants are fed in
stoichiometric proportion.
𝑚𝑜𝑙𝑒𝑠 𝑟𝑒𝑎𝑐𝑡𝑒𝑑 𝑛𝑓 − 𝑛𝑜
𝐶𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛 = =
𝑚𝑜𝑙𝑒𝑠 𝑓𝑒𝑑 𝑛𝑜
Fractional Conversion
For unreacted reactants, there are 2 types of conversion:
a- Single pass conversion
b- Overall conversion
The overall conversion should be >>> single pass conversion
Selectivity:
• Measure of the efficiency of the reactor in converting reagent to the desired product.
• It is the fraction of the reacted material that was converted into the desired product.
• If no byproducts are formed, then the selectivity is 100%.
𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑑𝑒𝑠𝑖𝑟𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑡

𝑆𝑒𝑙𝑒𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑢𝑛𝑑𝑒𝑠𝑖𝑟𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑡
Yield:
It's a measure of the performance of a reactor or a plant.
There are 2 types of yield:
a- Reaction yield (Chemical yield)
Reaction yield = Conversion * Selectivity
Where moles reagent converted includes that consumed in both main & side reactions.
Reaction yield = conversion when there is no side reactions take place.
b- Plant Yield
Plant yield is a measure of the overall performance of the plant and includes all chemical &
physical losses (during separation process).
Stoichiometric factor = theoretical moles of reagent required per moles of product produced in the reaction
balanced equation.
Energy balance
Law of thermodynamics – Energy can neither be created nor destroy
Input – out put = Accumulation
1
▪ Kinetic =𝐸𝑘 = 𝑚𝑣 2 (due to motion)
2
▪ Potential = 𝐸𝑝 = 𝑚𝑔𝑧 (due to elevation)

▪ Internal = due to molecular interaction
▪ Q= heat , ΔT= difference in temp between system and surrounding
▪ W= response to driving force
Combustion Reactions:
Complete 𝐶𝐻4 + 2𝑂2 → 𝐶𝑂2 + 2𝐻2 𝑂
Combustion
Incomplete 𝐶𝐻4 + 1.5 𝑂2 → 𝐶𝑂 + 2𝐻2 𝑂
Excess air is used in combustion to:

1- Ensure complete combustion.
2- Minimize CO and smoke formation.
% excess air = oxygen;
Air = 79% N2 + 21% O2 by moles
Air = 77% N2 + 23% O2 by mass
▪ Excess O2 (air) is calculated from the complete combustion equation, based on conversion of
all C→ CO2, S→ SO2 & H→ H2O.
▪ Excess air means that more air will be heated (i.e. high energy losses).
Expressing the Composition of a Material Stream:
𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑚𝑎𝑠𝑠 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑚𝑜𝑙𝑒𝑠

𝑀𝑎𝑠𝑠 𝐹𝑟𝑎𝑐𝑡𝑖𝑜𝑛 = =
𝑇𝑜𝑡𝑎𝑙 𝑠𝑡𝑟𝑒𝑎𝑚 𝑚𝑎𝑠𝑠 𝑡𝑜𝑡𝑎𝑙 𝑠𝑡𝑟𝑒𝑎𝑚 𝑚𝑜𝑙𝑒𝑠
𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑣𝑜𝑙𝑢𝑚𝑒
𝑀𝑎𝑠𝑠 𝑣𝑜𝑙𝑢𝑚𝑒 =
𝑇𝑜𝑡𝑎𝑙 𝑠𝑡𝑟𝑒𝑎𝑚 𝑣𝑜𝑙𝑢𝑚𝑒
Choice of a basis for Calculations:
▪ A basis of calculation for a process is an amount or flow rate of one of the process streams,
preferably that stream with known composition.
▪ The basis may be a period of time for example, hours, or a given mass of material.
For continuous process (production or feed rate - kg/hr, ton/day)
✓ Basis is1 hr or 1 operating day (unit of Time)
For batch process (production or feed rate - kg/batch , ton/batch)
✓ Basis is 1 batch.
If the flow rates are not given
• For composition given as mass fraction (in case of liquids or solids),
✓ basis - 1 or 100 lbm or kg.
• For composition given as mole fraction (in case of gases),
✓ basis -1 or 100 lbmol or kmol.
Choice of the system boundary
The system chosen must have a degree of freedom = 0.0 in order to be able to be solved (i.e. No. of
equations = No. of unknowns).
For any reactive system, the following parameters should be defined:
✓ Yield or conversion.
✓ % Excess if present.
✓ Concentrations (strength) of reactants & products streams.
✓ Recovery.
𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑓𝑖𝑛𝑎𝑙𝑙𝑦 𝑜𝑢𝑡 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑝𝑙𝑎𝑛𝑡

𝑅𝑒𝑐𝑐𝑜𝑣𝑒𝑟𝑦 =
𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑝𝑟𝑜𝑑𝑢𝑐𝑒𝑑 𝑓𝑟𝑜𝑚 𝑡ℎ 𝑟𝑒𝑎𝑐𝑡𝑜𝑟
Problem:
If air consists of 77% by weight of nitrogen and 23% by weight of oxygen calculate:
✓ the mean molecular weight of air
✓ the mole fraction of oxygen
✓ the concentration of oxygen in mole/m3 and kg/m3 if the total pressure is 1.5
atmospheres and the temperature is 25 °C.
Exothermic
Reactive
system
System Endothermic
Non reactive
system
Reactive System:
▪ Calculate the rate of heat addition or removal from the system to maintain the reaction mixture at the
desired temperature to ensure certain degree of conversion.
▪ Calculate the flow rates of heating or cooling utilities required.
▪ Calculate the heat transfer area required for heating or cooling.
Non-Reactive System:
▪ Heat transfer takes place without chemical reaction Eg.Vapourizer, condenser, cooler, Evaporator
(-) Exothermic
reaction
ΔH
(+) Endothermic
reaction
For a reaction A + 2 B → C = -240 kJ/mol
1 mole of A react with 2 mole of B to produce 1 mole of C = 240 kJ.
If 100 mole of B reacts with 50 mole of A the heat produced = 1200 kJ.
Equipment Sizing
▪ Calculation of reactors volume & dimensions. Batch
▪ Calculation of storage (holding) tank volumes. Reactors
Continuous
Volume of the reactor
After calculation of the reactor volume, its dimensions can be calculated
Note: For mixed phase reaction the volume is calculated based on the
gas volume.
Storage (Holding) Tank:
Storage tank is used for raw materials & final products.
Holding tanks is used in case of batch process.
Equipment design and specification
▪ preparing the specifications for individual pieces of equipment
▪ acquainted with methods for fabricating different types of equipment
▪ Design data must be developed, giving sixes, operating conditions, number and location of openings,
types of flanges and heads, codes, variation allowances, and other information
▪ chemical engineer must supply the basic design information.
Scale In Design
▪ Heat exchangers, distillation columns, pumps, and many other types of conventional equipment can
usually be designed adequately without using pilot-plant data
▪ limitations of scale-up methods and should know how to select the essential design variables
Safety Factors
▪ Each piece of equipment should be designed to carry out its necessary function.
▪ Uncertainties are involved, a reasonable safety factor can be applied.
▪ The role of the particular piece of equipment must be considered
▪ Fouling, occur during operation, should never be overlooked
The magnitudes of safety factors are dictated by
✓ economic or market considerations
✓ the accuracy of the design data and calculations
✓ potential changes in the operating performance
✓ background information + available on the overall process
✓ the amount of conservatism used in developing the individual components of the design
Specification
▪ The manufacturer can usually quote a lower price and give better guarantees for standard equipment than
for special equipment.
▪ Valuable information can be obtained from equipment manufacturers who specialize in particular types of
equipment
▪ The engineer should evaluate the design needs and prepare a preliminary specification sheet for the
equipment.
Preliminary specifications for equipment should show the following:
1. Identification 2. Function 3. Operation 4. Materials handled 5. Basic design data 6. Essential controls 7.
Insulation requirements 8. Allowable tolerances 9. Special information and details
Material of Construction
▪ important factors in the choice and design of equipment: Chemical resistance and physical properties of
constructional materials
▪ corrosive action of any chemicals that may contact the exposed surfaces
▪ Possible erosion caused by flowing fluids or other types of moving substances must be considered
additional factors
✓ Structural strength
✓ resistance to physical or thermal shock
✓ cost, ease of fabrication
✓ necessary maintenance
✓ general type of service required, including operating temperatures and pressures
Plant location and layout
Plant location
Key factors to consider
▪ Low cost of production/ distribution

▪ Scope for expansion
▪ Safe living condition
▪ Environmental and political issues
Raw materials availability
✓ For large volume of raw material nearby source permits considerable reduction in
transportation and storage material.
✓ Attention should be given for the price of the raw materials, distance from the source
of supply, freight or transportation expense, availability and reliability of supply,
purity of the raw materials, and storage requirements.
Markets
✓ Location of markets or intermediate distribution centres affects the cost of product
distribution and the time required for shipping
✓ Buyer usually finds it advantageous to purchase from nearby sources.
Energy availability
✓ power and fuel can be combined as one major factor in the choice of a plant site
✓ Plants using electrolytic processes are often located near large hydroelectric
installations
✓ location near a source of fuel supply may be essential for economic operation
Climate
✓ located in a cold climate, costs may be increased for construction of protective

shelters around the process equipment;
✓ special cooling towers or air-conditioning equipment may be required if the
temperatures are high
Transportation facilities
✓ Water, railroads, and highways are the common means of transportation used by
major industrial concerns and possibilities of canal, river, lake, or ocean transport
must be considered
✓ The kind and amount of products and raw materials determine the most suitable type
of transportation facilities.
Water supply
✓ Industries use large quantities of water for cooling, washing, steam generation, and as
a raw material, large river or lake, deep wells or artesian wells are preferable if the
amount of water required is not too great
✓ If water supply shows seasonal fluctuations, then it is desirable to construct a
reservoir or to drill several standby wells
✓ The temperature, mineral content, silt or sand content, bacteriological content, and
cost for supply and purification treatment must also be consider
Waste disposal
✓ many legal restrictions have been placed on the methods for disposing of waste materials from
the process industries
✓ site selected for a plant should have adequate capacity and facilities for correct waste disposal
Labor supply
✓ labor available in the vicinity of a proposed plant site must be examined
✓ Consideration should be given to prevailing pay scales, restrictions on number of hours worked
per week
Taxation and legal restrictions
✓ State and local tax rates on property income, unemployment insurance, and similar items vary
from one location to another
✓ local regulations on zoning, building codes, nuisance aspects, and transportation facilities can
have a major influence on the final choice of a plant site.
Site characteristics
✓ topography of the tract of land and’ the soil structure must be considered since either or both
may have a pronounced effect on construction costs
✓ even though no immediate expansion is planned, a new plant should be constructed at a location
where additional space is available
Flood and fire protection
✓ Many industrial plants are located along rivers or near large bodies of water, and there are risks
of flood or hurricane damage
✓ the regional history of natural events of this type should be examined and the consequences of
such occurrences considered
✓ Protection from losses by fire is another important factor in selecting a plant location.
Flood and fire protection
✓ Many industrial plants are located along rivers or near large bodies of water, and there are risks of
flood or hurricane damage
✓ the regional history of natural events of this type should be examined and the consequences of
such occurrences considered
✓ Protection from losses by fire is another important factor in selecting a plant location.
Community factors
✓ character and facilities of a community can have quite an effect on the location of the plant
✓ Cultural facilities of the community are important to sound growth.
For a preliminary survey, the first four factors should be considered
PLANT LAYOUT
▪ Before detailed piping,structural, and electrical design, the layout of process units must be planned
▪ Determining construction and manufacturing costs
▪ Proper layout include arrangement of processing areas, storage areas, and handling areas in efficient
coordination
1. New site development or addition to previously developed site
2. Type and quantity of products to be produced
3. Type of process and product control
4. Operational convenience and accessibility
5. Economic distribution of utilities and services
6. Type of buildings and building-code requirements
7. Health and safety considerations
8. Waste-disposal requirements
9. Auxiliary equipment
10. Space available and space required
11. Roads and railroads
12. Possible future expansion
Preparation of the Layout
▪ Elementary layouts are developed - fundamental relationships between storage space and
operating equipment.
▪ The next step requires consideration of the safe operational sequence and gives a primary
layout based on the flow of materials, unit operations, storage, and future expansion
▪ Detailed recommendation can be presented, and drawings and elevations, including isometric
drawings of the piping systems, can be prepared
▪ Errors in a plant layout are easily located when three-dimensional models are used, since the
operations and construction engineers can immediately see errors
▪ Models are very useful during plant construction and for instruction and orientation purposes
after the plant is completed.
Case study 1
Well known company consider building a plant in a city
They spot a vacant area next to a power plant
Power company could supply them with steam at reasonable price – they would not need to built stem
generator as been planned
Case study 2
Satellite plant either use a by-product or waste stream from adjacent plant or supply needed chemical to
neighbour plant. Nearby plant determines the location of plant
1965 Dow chemical company at midland Michigan USA gave an adjoin site to American salt company,
both got benefited each other
Excess salt from Dow after bromine recovery from brine was transported at low cost (pipeline). Dow
company sell the salt instead of pumping back to ground
Case study 3
Paper mill used filler, kaolin clay and expensive wood pulp as starting material to make acid paper
Precipitated calcium carbonate has been accepted as cost effective filler, companies deliver PCC to
paper mill from onsite production facilities with paper mill resources (land electricity, water and lime
kiln gas), Its cost effective compare to merchant supply and transportation cost is eliminated
Process developments involve the following categories
1. Design
2. Flow sheet
3. Simulation
Design
Plant design is the creative activity where we generate ideas and translate them into inter
connected equipment and processes for producing new material or significantly upgrading
the value of existing material in a safe, reliable and economic way
Flow Sheet
The flowsheet is the key document or road map in process design
✓ diagrammatic representation of the process steps with their interconnections (to simplify visualization,
manufacturing procedure and to indicate the quantities of materials and energy transfer).
✓ Theses diagram may be divided into following types
1. Qualitative – indicates flow of material unit operation involved equipment necessary and special
information on operation temperature and pressure
2. Quantitative – shows quantities of material require for the process operation
3. Combined details - shows the location of temperature and pressure regulators and indicators, as well as
the location of critical control valves and special instruments
Importance of flow sheet
✓ Shows the arrangement of the equipment selected to carry out the process.
✓ Shows the streams concentrations, flow rates & compositions.
✓ Shows the operating conditions.
✓ Basis for comparison of operating performance with design.
Process Flow
Diagram (PFD)
Block Diagram
Piping and
Flow sheet Instrumentation
Diagram (P&ID)
Pictorial flow sheet
Utility
FlowsheetDiagram
(Process Engineering
Utility Flow Diagram
(PEUFD)
Process
Safeguarding Flow
Diagram (PSFD)
Block Diagram
Process Utility Flow Diagram
Process Flow
• Emphasis on process flow
Diagram
Piping and
Instrumentation • Emphasis Process control
Diagram
Piping and Instrumentation Diagram (P & ID) (mechanical flow diagram)
• P&ID diagram shows the arrangement of the process equipment, piping, pumps, instruments, valves and
other fittings.
• Important role in the design, installation and day to day maintenance of the control system
P & ID Represents
It should include:
• All process equipment identified by an equipment number.
• All pipes identified by a pipe size, material of construction and line identification number.
• All pumps identified by a suitable code number.
• All Ancillary fitting shown with identification number (Cold and hot insulation – marked)
• All Utility lines/ service line should be included
• Any Elevation of equipment with height must be mention
• All valves with an identified size and number.
• All control loops and instruments
Analyzer Element (Chemical
AE
Composition)
Air Operated Valves AOV
Burner Element (flame detector) BE
Conductivity Recorder CR
Differential Pressure DP
Density Transmitter DT
Flow Controller FC
Flow Control Valve FCV
Flow Element FE
Flow Sight Glass FG
Flow Hand Control (manual) FHC
Hand Switch in Flow Loop FHS
Flow Indicator FI
Flow Indicating Controller FIC
Flow Meter FM
Flow Quantity Recorder FQR
Flow Quantity Indicator FQI
Flow Recorder FR
Flow Recorder Controller FRC
Flow Switch FS
Flow Transmitter FT
Flow Transducer FTD
Hand Operated Control Valve HCV
Hand Switch HS
Level Controller LC
Level Control Valve LCV
Level Gage Glass LG
Level Hand Control (manual) LHC
Level Indicator LI
Level Indicating Controller LIC
Level Recorder LR
Level Switch LS
Level Transmitter LT
Level Transducer LTD
Motor Operated Valve MOV
Motion Transmitter MT
Pressure Alarm PA
Pressure Controller PC
Pressure Control Valve PCV
Differential Pressure Indicator PDI
Ph Transmitter PHT
Pressure Indicator PI
Press. Indicating Controller PIC
Press. Indicating Transmitter PIT
Pressure Recorder PR
Pressure Switch PS
Pressure Transmitter PT
Pressure Transducer PTD
Pressure Relief Valve PZV
Temp. Indicating Controller TIC
Temp. Recorder TR
Steam Trap or Airvent TRAP
Temp. Switch TS
Temp. Switch Alarm TSA
Temp. Transmitter TT
Temp. Transducer TTD
Thermowell TW
Weight Measuring Element WE
Annunciator XA
Vibration Detector XVE
Vibration Switch XVS
Factor Rating Method
The plant location A, B and C are assigned with respect to three factors. The weight to the factors (W1,
W2, W3) are also mentioned. Find the best plant location among these. Find the sum of weighted score for
each location. The site with the highest weighted score is selected as the best choice.
Location Factors
Availabilit Availabilit Proximity
y of skilled y of raw to the
labor material markets
(W1=0.4) (W2=0.35) (W1=0.25)
A 65 60 55
B 70 45 90
C 60 95 50
Location Factors Total
Availability of skilled Availability of raw Proximity to the
labour (W1=0.4) material (W2=0.35) markets
(W1=0.25)
A 65 *0.4=26 60*0.35=21 55*0.25=13.75 60.75
B 70*0.4 45 90 66.25
C 60 95 50 69.75
Factors affecting plant design
1) Policies of management
2) Plant location
3) Nature of the product
4) Volume of production
5) Availability of floor space
6) Nature of manufacturing process
7) Repairs and maintenance of equipment and machines.

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Affiliated to VTU, Belagavi,

Approved by AICTE, New Delhi,

Process Engineering Economics

Prepared By: Dr. Augusta Pachathu

▪ Overall planning of a plant

Knowledge Apply Develop

Chemical products Produced: Large volume, Eg sulfuric acid, nitrogen,

Produced: Large volume, n-butyric acid, barium

▪ Development of design database

• Latest design, flowsheet, equipment and simulation

• Expired patent provide information

Arrangement of process involves degree of conversion, reaction rate, competing side

1. Technical factors a. Process flexibility b. Continuous operation c. Special

2. Raw materials a. Present and future availability b. Processing required c.

3. Waste products and by-products a. Amount produced b. Value c. Potential

5. Plant location a. Amount of land required b. Transportation facilities c.

6. Costs a. Raw materials b. Energy c. Depreciation d. Other fixed charges e.

8. Process considerations a. Technology availability b. Raw materials common with other

▪ Pilot plant/semi work scale desirable for accurate design

Method for carry out the design may be divided

1. Order of magnitude design

First two- used to determine the level of investment required

✓ Utilize flow sheet developed in process creation

✓ Establish workable manufacturing process

✓ After method development comparison of design need to be made

Vessels – size, holdup time, MOC, packing/ baffles

Pumps and compressors - type, power requirement, pressure difference,

✓ material and energy balances

✓ process conditions on temperature and pressure variation

✓ Raw material and product specification

✓ yields, reaction rates and time cycle

▪ Purchase standard equipment and material for construction

▪ Piping diagram included

▪ Safety condition and environment impact

Following list of items to be consider for the feasibility survey

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

over individual process to set theprocess

Material balance is also useful tool for the following:

The overall conversion should be >>> single pass conversion

𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑑𝑒𝑠𝑖𝑟𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑡

▪ Potential = 𝐸𝑝 = 𝑚𝑔𝑧 (due to elevation)

Complete 𝐶𝐻4 + 2𝑂2 → 𝐶𝑂2 + 2𝐻2 𝑂

Excess air is used in combustion to:

Expressing the Composition of a Material Stream:

𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑚𝑎𝑠𝑠 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑚𝑜𝑙𝑒𝑠

𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑓𝑖𝑛𝑎𝑙𝑙𝑦 𝑜𝑢𝑡 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑝𝑙𝑎𝑛𝑡

desired temperature to ensure certain degree of conversion.

▪ Calculate the flow rates of heating or cooling utilities required.

▪ Calculate the heat transfer area required for heating or cooling.

For a reaction A + 2 B → C = -240 kJ/mol

1 mole of A react with 2 mole of B to produce 1 mole of C = 240 kJ.

Volume of the reactor

After calculation of the reactor volume, its dimensions can be calculated

Key factors to consider

▪ Low cost of production/ distribution

✓ located in a cold climate, costs may be increased for construction of protective

For a preliminary survey, the first four factors should be considered

Well known company consider building a plant in a city

They spot a vacant area next to a power plant

The flowsheet is the key document or road map in process design

✓ Theses diagram may be divided into following types

Air Operated Valves AOV

Burner Element (flame detector) BE

A 65 0.4=26 600.35=21 55*0.25=13.75 60.75