JEFERSON COSTA´S

THE TOP 10
CHEMICAL PROCESS
ENGINEERING POST
2023 EDITION
Simplifying Chemical Process Engineering and
Plant Design for Students, Graduates and
Engineers

MORE THAN 3.2 MILLIONS IMPRESSIONS ON LINKEDIN

 “Although people think that Chemical Process Engineers perform
calculations all the time, in fact, their main task is to solve problems using
analytical thinking and to integrate information between different people
and disciplines.”
Jeferson Costa

www.jefersoncosta.com
 Contents
PREFACE ........................................................................................................................................ 4
CRITERIA OF SELECTION ................................................................................................................ 5
10º POSITION: HAVE YOU EVER USED MOODY DIAGRAM FOR PRESSURE DROP CALCULATION
IN YOUR PROFESSIONAL LIFE? ...................................................................................................... 6
9º POSITION: HEAT EXCHANGERS' RULES OF THUMB FOR CHEMICAL PROCESS ENGINEERS ...... 7
8º POSITION: READ THIS IF YOU ARE A CHEMICAL PROCESS ENGINEER INTERESTED ONLY IN CV
SIZING FOR CONTROL VALVES....................................................................................................... 8
7º POSITION: WHAT IS THE SECRET FOR READING P&ID? ............................................................ 9
6º POSITION: PROCESS DESIGN OR PLANT DESIGN: WHAT CHEMICAL PROCESS ENGINEERS DO?
..................................................................................................................................................... 10
5º POSITION: PUMP HEAD, WHAT MATTERS FOR CHEMICAL PROCESS ENGINEERS? ............... 12
4º POSITION: WHAT COMES FIRST: LAYOUT OR P&ID? CONSIDERATIONS FROM A CHEMICAL
PROCESS ENGINEERING IN PLANT DESIGN ................................................................................. 13
3º POSITION: WHICH PROCESS SIMULATION SOFTWARE BEST FIT YOUR NEEDS? .................... 14
2º POSITION: WHY 2 PROCESS ENGINEERS WITH SAME PROCESS INPUTS WILL NOT GET THE
SAME VESSEL SEPARATOR DIMENSIONS .................................................................................... 15
1º POSITION: WHAT A CHEMICAL PROCESS ENGINEER SHOULD CONSIDER WHEN DEFINING
REFLUX RATIO IN DISTILLATION COLUMN? ................................................................................ 16
WHO IS JEFERSON COSTA ........................................................................................................... 17

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 PREFACE

WHAT THIS EBOOK IS ABOUT

(AND WHAT IT’S NOT ABOUT)

Hey, my name is Jeferson Costa.

Before we get started, I want to introduce myself and let you know what this book is about (and more
importantly, what it’s not about).

I started sharing content on LinkedIn in ending of 2019. Since then, I have been teaching students,
graduates and engineers how to work with chemical process engineering and plant design. The main
purpose of these post is share my knowledge and expertise with chemical process engineers not familiar
with the real life in plant design. On each post I do on social media, I try my best to share a chemical
process engineer´s point for the tasks and activities you will find in plant design.

In this eBook, you will not find differential equations, you will not find how to do calculation, nor deep
explanation related to chemical process engineering fundamentals. All of them are very important for a
chemical process engineer, and I believe you learnt most of them during your time in University/College.

This eBook is not also for experienced chemical process engineers with background in plant design. If you
have 3 or more years of experience in plant design the chances are I do not have much to teach you
because my target audience is students, graduates and engineers with no experience in plant design.

On this eBook, you will find the 10 top I did on LinkedIn in 2023 with the following question on my mind:
What I can write to teach students, graduates and engineers more about how to work with chemical
process engineering and plant design. What I can share from my experience working in plant design since
2007 that can build on them a chemical process engineer´s point of view related to their roles and
responsibilities in plant design.

Expectations set, I hope you enjoy the reading and most important, get at least one insight or at least one
idea to help you in your students, in your job interview, in your job activities, or just that you get
something from this eBook that makes you fill you have boosted even a little bit your chemical process
engineering career in plant design.

That said, do not hesitate on sharing your comments and feedback with me at my social media on by
email at jeferson@jefersoncosta.com.

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CRITERIA OF SELECTION

We are about to start and I would like to share with you the criteria used to select the 10 top chemical
process engineering post 2023 edition.

In the last 365 days, I have shared more than 100 technical post on my LinkedIn feed (written or video)
leading to 3,288,708 impressions in the platform.

Impression are the total number of times a post is displayed onscreen. This number is an estimate
measure by LinkedIn and may not be precise, but shows how important a post is for the audience in
LinkedIn, in this case, for people interested on chemical process engineering and plant design.

Although LinkedIn algorithm is a secret and not well understood, the number of impressions has
relationship with the total number of engagements on a posts, including reactions, comments, and
reposts. Engagements from organizations aren't included in this statistics.

More people linking, commenting and sharing a post, higher the chances to LinkedIn distribute the post
to more people in order that it gets more likes, comments and shares until the cycle life of the post ends.

Based on that, I have selected the top 10 post I did on LinkedIn in 2023, classified based on their number
of impressions. Let´s start from the lowest number of impressions, 10º position, to the 1º position, higher
number of impressions.

On each post, you will find their respective statistics. Besides that, you will be able to access the original
post and add your comments just clicking in the notes available in the footer. I encourage you to get access
to the original post because in some of them you will find additional information added by experts and
other LinkedIn users.

Number of times all my post were displayed for LinkedIn users in 2023

Ready to booster your chemical process engineering and plant design career? Take a look at the post
number 10º in the next page.

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10º POSITION: HAVE YOU EVER USED MOODY DIAGRAM FOR PRESSURE DROP CALCULATION IN YOUR
PROFESSIONAL LIFE?1

Let me confess you that in my 15 years and more

as a chemical process engineer in plant design, I
never used Moody diagram for pressure drop
calculation. And I am very blessed for that.

As a junior engineer in my first job in plant design,

one of my tasks was to deal with line list in a
Polypropylene revamp. There were more than 100
lines where I should verify operating conditions
(pressure, temperature, flow), pipe size, pressure
drop, design condition for pressure test and safety
valve set point and so on.

Although, I got familiar with pressure drop hand calculation in University, in "real life", I was able to
perform it using process simulation software that mainly use Colebrook equation, which for sure, saved a
lot of time to me and for the company.

The Moody chart or Moody diagram (also Stanton diagram) is a graph in non-dimensional form that
relates the Darcy–Weisbach friction factor fD, Reynolds number Re, and surface roughness for fully
developed flow in a circular pipe. It can be used to predict pressure drop or flow rate down such a pipe.

In fluid dynamics, the Darcy–Weisbach equation is an empirical equation that relates the head loss, or
pressure loss, due to friction along a given length of pipe to the average velocity of the fluid flow for an
incompressible fluid. The equation is named after Henry Darcy and Julius Weisbach. Currently, there is no
formula more accurate or universally applicable than the Darcy-Weisbach supplemented by the Moody
diagram or Colebrook equation.

The phenomenological Colebrook–White equation (or Colebrook equation) expresses the Darcy friction
factor f as a function of Reynolds number Re and pipe relative roughness ε / Dh, fitting the data of
experimental studies of turbulent flow in smooth and rough pipes. The equation can be used to
(iteratively) solve for the Darcy–Weisbach friction factor f.

Picture/source: Wikipedia

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9º POSITION: HEAT EXCHANGERS' RULES OF THUMB FOR CHEMICAL PROCESS ENGINEERS2

Chemical process engineers need to design, select,

and optimize heat exchangers based on the specific
requirements of the process they are working on.
This involves considerations such as heat transfer
rates, pressure drops, materials compatibility, and
safety. Different types of heat exchangers,
including shell-and-tube, plate, finned-tube, and
more, may be chosen depending on the
application.

A heat exchanger is a critical piece of equipment

serving several important purposes:

Temperature Control: Heat exchangers are used to control the temperature of process fluids. They can
either heat a fluid (by transferring heat from a hot fluid to a cold one) or cool it (by transferring heat from
a hot fluid to a cooling medium).

Energy Efficiency: They help in recovering and reusing heat energy within a process. This can lead to
significant energy savings and cost reduction.

Phase Change: Heat exchangers are crucial in processes involving phase changes, such as condensation
or vaporization. They enable efficient transfer of heat during these transitions.

Preventing Contamination: When dealing with toxic or reactive substances, it's important to isolate them
from the environment. Heat exchangers allow for indirect heating or cooling, preventing contamination
or reactions between the process fluid and the external environment.

Maintaining Optimal
Reaction Conditions:
In chemical
reactions,
maintaining a
specific temperature
is often critical for
controlling reaction
rates and product
quality. Heat
exchangers help in
achieving and
maintaining these
conditions.

Cooling Water Systems: Many chemical processes generate a significant amount of heat that needs to be
dissipated. Heat exchangers are used to transfer this heat to cooling water or other cooling media,
ensuring the safe operation of equipment.

Refrigeration and Cryogenic Processes: In processes involving low temperatures, heat exchangers are
essential for achieving and maintaining cryogenic conditions.

Heat Recovery: In some cases, heat exchangers are used to recover waste heat from one part of a process
and use it in another, improving overall energy efficiency.

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8º POSITION: READ THIS IF YOU ARE A CHEMICAL PROCESS ENGINEER INTERESTED ONLY IN CV SIZING FOR
CONTROL VALVES3

Many people believe that cv calculation is what

really matters for control valves sizing and
selection. If you are one of them, I have bad news
for you.

To erect and operate an industrial plant Companies

need control valves installed in the field. To do
that, you know how to fill an specification sheet
(DS) and how to evaluate documentation from
vendor. In an interview, you will get more credits if
you show how to purchase a control valve. CV
sizing? It is the minimum and to be sincere, any supplier software is able to do this. Below, I will tell you
3 major points when defining a control valve as a chemical process engineer.

1) Safe position

It is mandatory you define the safe position of a valve when its energy source (instrument air, power etc)
is cut off. The wrong selection will lead to unsafe conditions and it process engineer roles to define this.

2) Ingress Protection

Electric/electronic components of the control valve must be protected from dust and water. When filling
a DS you will need know where the control valve will be located. And please do not use IP68 as standard.

3) Hazard Area Classification

Again control valve electric/electronic components must be purchased according to the place where it
will be installed. There are different techniques to prevent ignition of a flammable source. So, you need
to define the Hazard Area Classification to the supplier. Not all component needs to be explosion proof.

4) Before I Go

But Jeff, Control valve specification is not a role for instrumentation engineer? Let me tell you this week I
did technical evaluation of 5 different suppliers quotation where each proposal had 8 control valves (small
project). It is common in some companies the process engineer be responsible for control valve sizing,
selection and evaluation.

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7º POSITION: WHAT IS THE SECRET FOR READING P&ID?4

If you plan to work with chemical process

engineering and plant design reading,
understanding and developing P&ID is mandatory.
Regarding reading, I will tell you the secret to
reading any P&ID you find in your career. It is very
simple, once I tell you.

The P&ID of an industrial plant consists of a series

of sheets schematically representing the
process/operations. Besides the cover, in the first
sheets available in the full package, you will find
the "symbols chart", "list of symbols" or a series of
sheets with similar nomenclature identifying how objects must read in a P&ID.

In the example below, you can find, for instance, CHEMICAL CODE. When reading a line identification,
based on chemical code you will identify which is the fluid inside the pipe. The same applies to equipment,
instruments, pipe material and so on. So, the first thing you must look for when getting a new P&ID is look
for the symbol chart because it is the only document that correctly informs what its object means in its
specific project.

Eventually, the symbol chart will be a specific document not included in the P&ID sheet. In this case, it
should be clearly identified in the P&ID cover/notes where it can be found.

PIPE NUMBERING

The piping system is identified in the P&ID in order that designers are able
to correctly choose materials, fitting, etc for design.

The most common way of pipe numbering or identification is by adding

to them its size, operational area, fluid service, sequential number, pipe
material, and flange pressure rating and in some cases, pipe insulation is
also informed. Although it will vary from one company to another, this
kind of numbering structure is very similar and you will be able to
understand important info from the stream represented in the P&ID
based on the pipe numbering.

For instance, take a look at the pipe 10”-CDG-8007-SS600-1”. In this case,

and with the help of a table of legends, we could find that this pipe has
10” size, its service is Cooling Water Supply, i. e., it is cooled water before
passing through heat exchangers for temperature transfer, operating
area 80 (cooling water distribution), sequential 07 (probably exist at least
6 pipes designation before pipe 07), stainless steel as pipe material, flange
pressure rating of 600# and insulation of 1” thickness.

As you can see, understating a pipe number can review a lot of

information. And some of them have a direct influence on process
simulation.

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6º POSITION: PROCESS DESIGN OR PLANT DESIGN: WHAT CHEMICAL PROCESS ENGINEERS DO?5

Working with chemical process engineering and

plant design is much more than using process
simulation software like Aspen Hysys, Aspen Plus,
Unisim Design, DWSim and so on.

As a chemical process engineer, you need to get

familiar with a series of roles and activities that will
allow a plant to be installed.

As my career is built on all phases of a project, i.e.,

since its conceptual design to startup and plant
troubleshooting. I do not differentiate process
design from plant design, however you can find below both definition available on Coulson and
Richardson’s Chemical Engineering Series.

PROCESS DESIGN

Process design, which covers the steps from the initial selection of the process to be used, through to the
issuing of the process flow-sheets; and includes the selection, specification and chemical engineering
design of equipment. In a typical organization, this phase is the responsibility of the Process Design Group,
and the work is mainly done by chemical engineers. The process design group may also be responsible for
the preparation of the piping and instrumentation diagrams.

PLANT DESIGN

Plant design, including the detailed mechanical design of equipment, the structural, civil and electrical
design, and the specification and design of the ancillary services. These activities will be the responsibility
of specialist design groups, having expertise in the whole range of engineering disciplines. Other specialist
groups will be responsible for cost estimation, and the purchase and procurement of equipment and
materials.

I specially prefer classifying plant design in basic engineering and detailing engineering.

This way, process design gets into basic engineering that includes process selection, equipment selection,
PFD/P&ID, functional description of the system and overall Plot Plan. A job in a technology licensor will
usually be limited by this scope of supply leading to the basic engineering package.

To complete the project and be able to install equipment, control valves, etc detailing engineering is
performed with equipment mechanical design; piping drawing with support structures, etc. This scope is
covered by Detailed Engineering companies.

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Picture source: Coulson and Richardson’s Chemical Engineering Series.

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5º POSITION: PUMP HEAD, WHAT MATTERS FOR CHEMICAL PROCESS ENGINEERS?6

To be able to install a pump in the field, we start

with the process heat and material balance (HMB)
and process flow diagram (PFD), followed up by
the piping and instrumentation diagram (P&ID).
These are essential tasks for any chemical process
engineer in plant design. But there is a step further
not understood by many fresher: datasheets.
Datasheets are the real document used for
purchasing equipment. They should have all
process, mechanical, electrical, instrumentation,
automation and so on information needed to
purchase the correct equipment to the correct place.

We are responsible for providing process data, i.e., stream inlet conditions: NPSHa, flow, composition
pressure and temperature. This information will lead to fluid mass density and viscosity. But to complete
the datasheet we need to inform one discharge condition. In pump datasheets, you will usually find
Discharge pressure, Differential pressure, and Total Head. Setting one, you define the other, but here you
must be alert that what matters for the pump supplier is Total Head, what matters for Process engineers
is discharge pressure.

WHAT IS TOTAL HEAD

The difference in height between the level of liquid in the suction and the height of a column of liquid that
the pump can achieve. Head is measured in length and is independent on the mass density.

WHAT IS PRESSURE

Discharge Pressure, on the other hand, is fluid dependent and is affected by gravity. Therefore, the same
head will generate a different pressure
depending on the fluid’s mass density.

The following formula shows the relationship

between differential pressure (dp) and head
(H): H=dp/(rho.g)

To summarize, you will calculate the required

pump discharge pressure in the HMB. Based
on the pump inlet condition, calculate the
pump differential pressure. This differential
pressure will be "translate" into the pump's
total head in length required to the process
according to fluid process data (composition,
inlet pressure and temperature). All this
information, plus flow and NPSHa, will be
filled in a datasheet. Congratulations, your
job is done and you can wait for the next step.

Picture Source: GRUNDFOS PUMP HANDBOOK

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4º POSITION: WHAT COMES FIRST: LAYOUT OR P&ID? CONSIDERATIONS FROM A CHEMICAL PROCESS
ENGINEERING IN PLANT DESIGN7

Last week I was told that "the process datasheet is

used to make the P&IDs and the P&IDs are the
basis for Plant layout and 3Dmodel!" and because
of that "Never ever a pump type shall be influenced
or the selection shall depend by piping
arrangement!" Do you agree with this sentence? I
will share with you my point of view.

Any plant design is created by business needs. It is

the client's (internal or external) demand that
drives us to do a series of engineering documents
to design, erect, commissioning, start and operate
a plant.

The first thing a chemical process engineer should verify is client requirements: Flow, pressure,
temperature and composition as the minimum. On the other side, we have the raw materials and utilities
available and their characteristics to reach product requirements. Between one and another, the chemical
process engineer will propose the process that best fits project's requirements in terms of process flow
diagram (PFD) and heat and material balance (HMB).

These documents are the basis for plant layout/plot plan. The plot plan is done after the preliminary PFD
because the project engineer must know which is the main equipment for the process in order to locate
them in the layout.

The PFD is not the

document to identify if the
process is in plain terrain or
in a skid, and that for sure
will influence equipment
selection, especially pumps
and compressors, because
of distances and elevation.
Of course, the area
available for the plant
installation must be already
defined (and it is not
defined by the process
engineer).

A preliminary P&ID will be

developed parallel with to
plot plan to show the main
equipment, instrumentation, controls and preliminary pipe size.

Process datasheet for pump and compressor, and its selection, will be issued only after layout and P&ID.
Not the opposite. Equipment selection, besides layout, will take into consideration also available
suppliers.

Picture Source: Cannon Industrial Design and Service Pty Ltd website.

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3º POSITION: WHICH PROCESS SIMULATION SOFTWARE BEST FIT YOUR NEEDS?8

Performing your job as a chemical process

engineer, eventually, you will see yourself with the
challenge of selecting the process simulation
software your company will apply to their process.
I got this challenge a few years ago.

From the point of view of your manager, the first

selection criteria will be the budget. This kind of
tool can easily cost around $20,000~30,000
USD/year for a single stead-state access. It may be
of less concern for big companies, or in the US or
Europe. But for emerging companies
(design/production) in developing countries,
contracting process simulation software from a big brand can be frustrating.

Putting money aside, your first task will be to identify what are the options available in the market, get in
touch with them, and ask for a quotation.

It is very important to identify first what the company's needs are. Will it be used for design? for operation
improvement? should dynamic mode be available? Do you have a batch process?

Some of these questions will filter the options you have. For instance, for batch processes, Aspen Hysys
may not be an option. If you are interested in dynamic mode, AVEVA PRO/II may not be of much help. For
the hydrolysis process, ProMax can be a good candidate. It will be used for a simple and known process,
maybe DWSIM can be a good fit.

In this post a list of 9 process simulation software for chemical process engineers.

Aspen Hysys

Aspen Plus

Unisim Design

Aveva Pro II

ProSim

ChemCAD NXT

Symmetry

DWSim

ProMax

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2º POSITION: WHY 2 PROCESS ENGINEERS WITH SAME PROCESS INPUTS WILL NOT GET THE SAME VESSEL
SEPARATOR DIMENSIONS9

These days, I have been involved with drawing

verification from a Detailing Engineering company.
As our project requires a vertical vessel separator,
as the process engineer from the Contractor, I
need to verify and give the approval for process
documents.

To have a vessel, separator installed in the field, it

is needed equipment purchase, that requires
equipment construction drawing based on process
datasheet.

Process datasheet in its side is a result of calculation memory performed based on heat and material
balance and design basis.

The design bases will define the assumptions for vessel diameter and height. Diameter calculation is
basically defined as a function of vapor flow and size of liquid droplet. And the seam to seam height, or
tangent to tangent height, that is a
function of vapor disengagement space,
liquid holdup, instrumentation and
safety martins.

Diameter depends on K factor (Droplet

size) and F (Design margin). Some
companies define a constant K and
ranges F, some other ranges K and set F
based on equipment service. Besides
that K and F varies if vessel has or not has
pad mesh.

Vessel height also have its own

considerations. Depending on company
guideline a vertical vessel can be
segmented in 3 regions, 7 or 8 regions
leading to different vessel height for the
same inlet process condition (flow,
pressure, temperature and
composition).

As a chemical process engineer working

with plant design, you need to be alert
with the following:

1) Have very clear what are the design basis for vessel calculations to your process.
2) Identify all constants and information used for sizing (at least for your boss). If client asks for them, it
will not be embarrassed.
3) Understand why equipment is placed and its service. Engineering guidelines are not to be used blindly.
4) Use GOOD SENSE. In the end, what matters is a design that works with minimum Capex and Opex.

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1º POSITION: WHAT A CHEMICAL PROCESS ENGINEER SHOULD CONSIDER WHEN DEFINING REFLUX RATIO
IN DISTILLATION COLUMN?10

Reflux ratio has a big role in distillation column

design, influencing not only the process but also
the economics of a project. Below some
consideration to chemical process engineers.

A tower theoretically requires infinite number of

trays at minimum reflux (R/Rmin=1) and hence the
corresponding capital investment for the system
comprising of the column, condenser, reflux drum,
reflux pump and reboiler is infinite. Higher
(R/Rmin) ratio reduces the number of trays and
consequently the column height but increases the
column diameter due to increased vapor and liquid traffic in the column. The corresponding reboiler and
condenser heat duties also increase. Thus, increase in (R/Rmin) from its minimum value of 1 decreases
the capital cost for the system from a very large value due to the effect of lowering of tower height
overriding the opposite effect of diameter increase. This reduction goes on up to a limit, beyond which
the capital cost increases again due to the effect of increase in tower diameter and also due to increased
heat duty and corresponding bigger sizes of the condenser and the reboiler. In the other hand, operating
cost increase with increase in the ratio (R/Rmin) as more energy is required.

The optimum reflux (Ropt) is a function of annualized Capex + Opex.

Usually (Ropt/Rmin) lie between 1.1

and 1.5, with the lower value
applying to a difficult separation and
the higher value to an easy
separation. However, optimal reflux
ratio is not sharply defined in most
cases and for greater operational
flexibility, columns are mostly
designed for reflux ratios slightly
higher than the optimum. In an
existing plant, a decrease in reflux
ratio can save only the utility cost
and a reflux sufficient to obtain the
desired product yield and purity
should be used. Usually the total
annual cost is dominated by the cost
of reboiler energy input except at
close to minimum reflux condition.
Also, in reality, often the credit for
additional separation overshadows the utility savings. In such cases of existing columns, the operating
(R/Rmin) used is as high as possible without causing flooding or entrainment in the column.

Source: Adapted from Process Equipment and Plant Design Principles and Practices. Elsevier.

Picture: Wolfram website.

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WHO IS JEFERSON COSTA

I am a chemical process with expertise in chemical process engineering and plant design working in an
energy company. I started my career in plant design in 2007, and since than I have been working in the
chemical, petrochemical, Oil & Gas industry and Refining.

My background includes all steps of plant design (feasibility studies, basic engineering, detailing
engineering, construction, commissioning, start up and plant troubleshooting), leadership and
cooperation with teams in Mexico and United States, and field activities in Brazil, Argentina, Uruguay and
Peru, as well as, expat to China.

Since 2018, I have helped thousands of people using my social media (YouTube, LinkedIn, Instagram and
Facebook) on how to work with chemical process engineering and plant design.

In 2023, I moved to France to work as a Senior Chemical Process Engineer in a big Oil Refining Licensor
company.

In Inprocess Booster training program, I teach students, graduates and engineers how to work with
chemical process engineering and plant design using process simulation software. The training program
has students from more than 40 different nationalities.

You can get more information about me, my trainings, social media and post at www.jefersoncosta.com.

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