CHEMICAL PROCESS DIAGRAM

SCOPE:Students will be able to know:-

Type of chemical process diagram- Block Flow Diagram (BFD)- Process Flow Diagram (PFD)- Piping and Instrumentation Diagram (P&ID)

How to read and draw BFD, PFD and P&ID

Process equipments symbol and numbering

3 Levels of Diagram-Block Flow Diagram (BFD) -Process Flow Diagram (PFD) -Piping and Instrumentation Diagram (P&ID)

BLOCK FLOW DIAGRAM (BFD)

Block Flow Diagram (BFD) BFD shows overall processing picture of a chemical complex: -Flow of raw materials and products may be included on a BFD -BFD is a superficial view of facility ChE information is missing

ReactorGas SeparatorToluene, C7H8 10,000 kg/hrHydrogen H2 820 kg/hrMixed Liquid75% Conversion of TolueneMixed Gas 2610 kg/hrBenzene, C6H6 8,210 kg/hrReaction : C7H8 + H2 C6H6 + CH4Figure 1.1: Block Flow Diagram for the Production of BenzeneC6H6CH4C7H8Example 1:

Example 2Production of Ethane from EthanolEthanol is feed to continuous reactor with presence of Acid Sulphuric catalyzer to produce ethylene. Distillation process then will be applied to separate ethylene-H2O mixture. Ethylene as a top product is then condensate with condenser to perform liquid ethylene. Hydrogenation of ethylene applies in another reactor with presence of Nickel catalyzer to produce ethane as a final product. Develop BFD for these processes.Reactor 1Reactor 2

Exercise 1:

Ammonia-air mixture is feed to the bottom stream of an absorber with flow rate of 10L/min. Water then feed to the upper stream of the same absorber with desired flow rate of 5L/min. There are two outputs from the absorber where upper stream is insoluble NH3 and bottom stream is NH3-Water mixture. This NH3-water mixture then feed up to a batch distillation column. The column produces ammonia gas as a top product which this product then will be condensate with a condenser to produce liquid ammonia. Develop Block Flow Diagram (BFD) for this process.

Answer 1AbsorberBatchDistillationWater 5 L/minAmmonia-air mixture 10 L/minInsoluble ammoniaAmmonia-water mixtureAmmonia gasCold water inHot water outAmmonia liquidCondenser

Exercise 2:

Ethanol-water mixture is feed to a batch distillation column. This distillation process will produce ethanol vapour at the top product which then condensate to produce liquid ethanol which then collected into a distillate product tank. This liquid ethanol and an acetic acid liquid from a acid feed tank are then feed to a reactor. An exothermic chemical reaction will producing ethyl acetate (a type of ester). Draw BFD for this chemical process.

Answer 2Batch distillationReactorDistillate product tankAcid feed tankEthanol-water mixtureCold water inHot water outEthanol liq.Ethyl acetateCondenser

PROCESS FLOW DIAGRAM

SCOPE:Students will be able to know:-

Process Unit symbology

How to read and draw PFD

Process equipments symbol and numbering

Process Flow Diagram (PFD)PFD shows all process engineering information: -The topology of the process showing the connectivity of all the streams and the equipment. -Use appropriate conventions consistency is important in communication of process information.

PFD will contains the following information:-All major pieces of equipment (descriptive name, unique equipment no.), pumps and valves.All the utility streams supplied to major equipments such as steam lines, compressed air lines, electricity, etc.All process flow streams: identification by a number, process condition, chemical composition.Basic control loops: showing the control strategy used to operate the process under normal operations.

PFD will contains the following information:--All major pieces of equipment (descriptive name, unique equipment no.), pumps and valves.-All the utility streams supplied to major equipments such as steam lines, compressed air lines, electricity, etc.

Process Unit SymbologySymbolDescriptionHeat exchangerWater coolerSteam heaterCooling coil

Process Unit SymbologySymbolDescriptionHeater coilCentrifugal pumpTurbine type compressorPressure gauge

Process Unit SymbologySymbolNameStripperAbsorberA separator unit used commonly to liquid mixture into gas phaseDescriptionA separator unit used commonly to extract mixture gas into liquid phase

Process Unit SymbologySymbolNameDistillationcolumnLiquid mixerA separator unit used commonly to crack liquid contains miscellaneous component fractions.DescriptionA process unit that used to mix several components of liquid.

Process Unit SymbologySymbolNameReactionchamberHorizontal tankor cylinderA process unit where chemical process reaction occursDescriptionA unit to store liquid or gas.

Process Unit SymbologySymbolNameBoilerCentrifugeA unit for heating.DescriptionA separator unit that to physically separated liquid mixture. (exp: oil-liquid)

Valve SymbologySymbolNameGate ValveCheck ValveGlobe ValveBall ValveButterfly Valve

Valve SymbologySymbolNameRelief ValveAngle ValveNeedle Valve3-Way ValveButterfly Valve

Example 3Production of Ethane from EthanolEthanol is feed to continuous reactor with presence of Acid Sulphuric catalyzer to produce ethylene. Distillation process then will be applied to separate ethylene-H2O mixture. Ethylene as a top product is then condensate with condenser to perform liquid ethylene. Hydrogenation of ethylene applies in another reactor with presence of Nickel catalyzer to produce ethane as a final product. Develop PFD for these processes.

Exercise 3:

Ammonia-air mixture is feed to the bottom stream of an absorber with flow rate of 10L/min. Water then feed to the upper stream of the same absorber with desired flow rate of 5L/min. There are two outputs from the absorber where upper stream is insoluble NH3 and bottom stream is NH3-Water mixture. This NH3-water mixture then feed up to a batch distillation column. The column produces ammonia gas as a top product which this product then will be condensate with a condenser to produce liquid ammonia. Develop Process Flow Diagram (PFD) for this process.

Answer 3Water 5 L/minAmmonia-air mixture 10 L/minInsoluble ammonia gasAmmonia-water mixtureAmmonia gasCold water inHot water outAmmonia liquid

T-100Absorber ColumnT-101Batch Distillation ColumnE-100Condenser

Process Unit Tagging and Numbering

Area No. 1Area No. 2

Area No. 3Y Letter

A/B LetterExampleEthanolH2SO4In PFDEthyleneEthylene liq.EthaneNiHydrogenCold water inHot water outP-100 AP-100 BIn real plant, it means like above

PFD will contains the following information:-All process flow streams: identification by a number, process condition, chemical composition.

Stream Numbering and Drawing - Number streams from left to right as much as possible. - Horizontal lines are dominant. YesNoNo

Example 4

Stream Information The Process Flow Diagram (PFD) (cont..)Since diagrams are small not much stream information

can be included. -Include important data around reactors and towers, etc. Flags are used

Full stream data,

123456781191012136002424300Stream Information - Flag The Process Flow Diagram (PFD) (cont..)600Temperature24Pressure10.3Mass Flowrate108Molar FlowrateGas FlowrateLiquid Flowrate

Example 5

Stream Information - Full stream data,

Stream Number12345678910Temperature (oC)25.035.035.035.035.060.3413854.045.1Pressure (psi)2832.231.031.030.245.131.324.039.02.6Vapor fractionMass flow (tonne/hr)10.313.30.8220.56.4120.50.369.220.911.6Mole flow (kmol/hr)108114.2301.01204.0758.81204.442.61100.8142.2244.0

Example 6

Stream Number12345678910Temperature (oC)25.035.035.035.035.060.341385445.1Pressure (psi)2832.231.031.030.245.131.324.0392.6Vapor fractionMass flow (tonne/hr)10.313.30.8220.56.4120.50.369.220.911.6Mole flow (kmol/hr)108114.2301.01204.0758.81204.442.61100.8142.2244.0

PFD will contains the following information:--Basic control loops: showing the control strategy used to operate the process under normal operations.

Example 7

Stream Number12345678910Temperature (oC)25.035.035.035.035.060.341385445.1Pressure (psi)2832.231.031.030.245.131.324.0392.6Vapor fractionMass flow (tonne/hr)10.313.30.8220.56.4120.50.369.220.911.6Mole flow (kmol/hr)108114.2301.01204.0758.81204.442.61100.8142.2244.0

QUESTIONS?