Chemical Plant Design

Process Flow Diagram

Fadhil Muhammad Tarmidzi, S.T., M.T. | Azmia Rizka Nafisah, S.T., M.T.
Block Diagram (BFD)
 3

Energy Block
Mass Block Diagram
Diagram

Information about quantity or rate of mass or energy per component (kg/hr or kJ/h)
 4

Energy Block
Mass Block Diagram
Diagram

Information about quantity or rate of mass or energy per component (kg/hr or kJ/h)
 5

Energy Block
Mass Block Diagram
Diagram

A B C D E

J I H G F
Process Flow Diagram
Introduction
 7

• Represents a quantum step up from the BFD in

terms of the amount of information that it
contains.
• Contains the bulk of the chemical engineering
data necessary for the design of a chemical
process.
 8

A typical commercial PFD will contain:

All the major pieces of All process flow
equipment in the streams will be shown
process will be and identified by a
represented on the number. A description
diagram along with a of the process
description of the conditions and
equipment. Each piece chemical composition
of equipment will have of each stream will be
assigned a unique included. These data
equipment number will be either displayed
and a descriptive name directly on the PFD or
included in an
accompanying flow
summary table.
 9

A typical commercial PFD will contain:

All utility streams Basic control loops,
supplied to major illustrating the control
equipment that strategy used to
provides a process operate the process
function will be shown during
normaloperations, will
be shown.
How to Draw PFD
 11

How to Draw PFD

drawn on large sheets of paper (for example, size
D: 24 in × 36 in)

Stream several connected sheets may be required for a

Information complex process
Process
Topology
certain information will be presented in
accompanying tables
Equipment
Information only the essential process information will be
included on the PFD

Basic Information on PFD

 12

Process Topology: Common Symbols

Heat Exchanger Pumps, turbines, compressor

Furnace/Fired heater Towers

Storage Tanks Vessels

 13

Process Topology: Common Symbols

Reactors
 14

Process Topology: Identification of the process equipment's icon

Codes General Format:
C
E
Compressor or turbine
Heat Exchanger
XX-YZZ A/B
H Fired Heater
P Pump
R Reactor
T Tower
TK Storage Tank
V Vessel
Y Designates an area within the plant
ZZ Number designation for each item in an equipment class
A/B Identifies parallel units or backup units not shown on a PFD
 15

Process Topology: Identification of the process equipment's icon

Example: General Format:

P-101A/B XX-YZZ A/B
 P- identifies the equipment as a pump.
 P-100 indicates that the pump is located in area
100 of the plant.
 P-101 indicates that this specific pump is number
01 in unit 100.
 P-101A/B indicates that a backup pump is
installed. Thus, there are two identical pumps, P-
101A and P-101B. One pump will be operating while
the other is idle.
 16

Process Topology: Information Provided in a Flow Summary

Required Information Optional Information
Component Mole Fractions
Stream Number
Component Mass Fractions
Temperature (c)
Individual Component Flowrates (kg/h)
Pressure (bar) Volumetric Flowrates (m3/h)
Vapor Fraction Significant Physical Properties
• Density
Total Mass Flowrate (kg/h) • Viscosity
• Others
Total Mole Flowrate (kmol/h)
Thermodynamic Data
Individual Component Flowrates (kmol/h) • Heat Capacity
• Stream Enthalpy
Stream Name
 17

Process Topology: Information Provided in a Flow Summary

Required Information
Stream Number
Temperature (c)
Pressure (bar)
Vapor Fraction
Total Mass Flowrate (kg/h)
Total Mole Flowrate (kmol/h)
Individual Component Flowrates (kmol/h)
18
 19

Stream Information
• Attached as Information Flag
• Flags are mounted on a staff connected to the
appropriate process stream.
• More than one flag may be mounted on a staff
 20

Stream Information: Utility Stream

• Utility streams are treated differently from process streams. Utility

streams, such as cooling water, steam, fuel, and electricity, rarely directly
contact the process streams.
• All these streams are utility streams and are not extended to the left or
right boundaries of the diagram, as were the process streams.
21
 22

▪ Each major piece of process equipment is identified by a number on the

diagram.
▪ A list of the equipment numbers along with a brief descriptive name for the
equipment is printed along the top of the diagram.
▪ The location of these equipment numbers and names roughly corresponds to
the horizontal location of the corresponding piece of equipment
 23

Combining Topology, Stream Data, and Control Strategy to

Give a PFD
Piping and
Instrumentation Diagram
(P&ID)
 25

Piping and Instrumentation Diagram (P&ID)

The piping and instrumentation diagram (P&ID), also known as mechanical flow diagram (MFD), provides
information needed by engineers to begin planning for the construction of the plant
 26

Piping and Instrumentation Diagram (P&ID)

 27

Piping and Instrumentation Diagram (P&ID)

 28

Piping and Instrumentation Diagram (P&ID)

 29

Equipment Information
 The final element of the PFD is the
equipment summary.
 This summary provides the
information necessary to estimate
the costs of equipment and
furnish the basis for the detailed
design of equipment.
 30

Equipment Summary
Example for pump:
 31

Hierarchy of Process Design

Identify and design the
Decide whether the Identify and define the heat-exchanger
process will be batch or recycle structure of the network or process
continuous process energy recovery system

1 3 5

2 4 6

Identify the Identify and design the Identify the utility

input/output structure general structure of the needed in the
of the process separation system equipments
32