Process Design 1

Overview of Process Synthesis

Learning outcomes
1. How to read and draw a process flow diagram (PFD)
2. How to synthesize a flowsheet for an entirely new process
3. How to review a flowsheet and check for completeness and
errors

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1. Process Flowsheeting

Block

6 7
Process

FCV
218

Engineering

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Block Flow Process Diagram (PFD)

For a process to synthesize ammonia from N2 and H2

N 2 + 3H 2 → 2 NH 3

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Block Flow Process Diagram (PFD)

For a process to synthesize ammonia from N2 and H2

N 2 + 3H 2 → 2 NH 3
Purge

recycle
N2
H2

N2, H2 N2, H2 NH3 Condenser

Reactor -35 oC
N2
Mixer H2
Conversion < 1.0
NH3

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Block Flow Process Diagram

Water vapour

Feed Product
Reaction &
Dehydrator Compression
Hydrogen Cooling
Purge

Air Recycle
Separation
Compression

Oxygen

 Major steps are conveyed but no equipment details.

 Sometimes the blocks may be process flow diagram symbols.

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Block Flow Plant Diagram

113 128

104 T-102 114 T-103

134

T-101
101
153
F-105

F-101 103 106

147
140
150

108 109 T-104 T-105 151

111
159
146

105 160

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Block Flow Diagrams - BFD
• To represent a process in a simplified form
• Conveys what is achieved in each step, not how it is achieved
• Consists of blocks representing different equipment or unit operations.
• Connected by input and output streams.
• Operating conditions like T, P, conversion and yield are included.

For a single process – Block Flow Process diagram

Complete chemical complex – Block Flow Plant diagram.

• Particularly useful in initial studies.

• Useful for conveying information to management.
• Useful to show inter-relation of stream.
• Useful in conveying global, not detailed, material balance.

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Block Flow Process Diagram

Toluene and hydrogen are converted in a reactor to produce

benzene and methane. The reaction does not go to completion, and
excess toluene is required. The non-condensable gases are
separated and discharged. The benzene product and the unreacted
toluene are then separated by distillation. The toluene is the
recycled back to the reactor and the benzene removed in the
product stream.

Draw a BFD for the process above.

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Flow Process Diagram

Non-condensable gases

Toluene
F mol/hr
Methane,
Benzene,
Reactor Toluene, Separator
Benzene
Hydrogen
Hydrogen Benzene,
H mol/h Toluene
Distillation
Liquid products

Recycle Toluene

C 7H8 + H2 → C 6H6 + CH4

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 The Process Flow Diagram
(PFD)

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The Process Flow Diagram (PFD)

1. The PFD contains most of the chemical engineering data necessary

for the design of a chemical process.
2. Conveys the major processing steps represented by the equipment

 Useful for conveying the heat and material balances

 Useful for conveying major pieces of equipment
 Useful for conveying processing conditions
 Useful for conveying utilities

PFD information can be divided into:

1. Process Topology – icons/symbols for equipment
2. Stream Information- number in diamond box.
3. Equipment Information – equipment data sheet.

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The Process Flow Diagram (PFD)

Howat Standards stipulate that a PFD must include the following:

1. All major piece of equipment in the process assigned a number and
name.
2. Every process flow streams.
3. Stream temperature and pressure included on in a separate table.
4. All auxiliary services – utilities.
5. Equipment sizes.
6. Basic process control and valves.

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The Process Flow Diagram (PFD)

Stream Number Temperature Pressure

Liquid Flowrate Molar Flowrate Gas Flowrate

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The Process Flow Diagram (PFD)

1. Should generally flow from left to right.

2. Should not be cluttered - use multiple sheets.
3. Should be in landscape with the bound edge at top.
4. The equipment should be drawn in approximately relative size, e.g.
towers larger than drums, exchangers larger than pumps etc.
5. The major towers and reactors are generally on one, or nearly one,
level.
6. The streams should have the minimum of direction changes.
7. The streams that enter across the boundary limits should be on the
left.
8. The streams that leave across the boundary limits should be on the
right.
9. The streams that move to the next sheet should leave on the right.
10. The streams that recycle to earlier sheets should leave on the left.

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Process Flow Diagrams

The following are examples from the Howat Standard Library of process
flow diagram symbols.

Cyclone
Mixer Cyclone
Autoclave

Conveyor Belt Ball Mill

Filter

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Process Flow Diagrams

Oil Burner Kettle Reboiler Shell and tube

Air-blown Cooler Heat Exchanger Heat Exchanger

Fired-heater

Cooling Tower
Boiler Cooling Tower

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Process Flow Diagrams

Centrifugal Pump Positive displacement Reciprocating Pump

Pump

Tray Colum Reacting Vessel Column Packed Column

Turbine Compressor
Covered Tank

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Process Flow Diagrams

Flow-sheet for polymer production [C&R Vol. 6]

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Process Flow Diagrams

Flow-sheet: simplified nitric acid process [C&R Vol. 6]

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Process Flow Diagrams

21 Reports
Process Flow Diagrams

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Process Flow Diagrams

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 The Piping and
Instrumentation Diagram
(P&ID)

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Piping & Instrumentation Diagram, P&ID

The P&ID also known as the Mechanical Flow Diagram, MFD or

Engineering Flow Diagram, EFD shows the arrangement of the
process equipment, piping, pumps, instruments, valves and other
fittings.

P&ID are used to convey the mechanical details of the plant. They
give every line, valve, connection in the process.

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Piping & Instrumentation Diagram, P&ID
On the P&ID:

• All process equipment identified by an equipment number. The equipment

should be drawn roughly in proportion, and the location of nozzles shown.

• All control loops and instruments, with an identification number.

• All pipes, identified by a line number. The pipe size and material of
construction should be shown.

• The type and size of all valves, control and block valves, with an identification
number must be shown.

• Ancillary fittings that are part of the piping system, such as steam traps must
be shown with an identification number.

• Pumps, identified by a suitable code number.

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Piping & Instrumentation Diagram, P&ID

 Note the complexity, depth of detail and labeling.

 Note that every flange on the tower is shown and tagged.

 Note that the lines are numbered giving codes relating to type of line, ASTM
code, size and insulation.

 Note that vents with valves and blind flanges are shown on the equipment.
Note that equipment not shown on the PFD is shown here. This equipment
tends to be minor but essential to continuous operation.

 Note that the level of detail for valving and control is substantially increased.

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Piping & Instrumentation Diagram, P&ID

Needle Valve Globe Valve Diaphragm Valve Powered Valve

Gate Valve Relief Valve Angle Valve Flange Valve

Ball Valve 3-Way Plug Valve Butterfly Valve Reducing Valve

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Piping & Instrumentation Diagram, P&ID

The P&ID also known as the Mechanical Flow Diagram, MFD or

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Piping & Instrumentation Diagram, P&ID

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