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INTRODUCTION TO
CHEMICAL ENGINEERING
PLANT DESIGN
CHAPTER 1 :
INTRODUCTION TO PROCESS
DESIGN
CHAPTER 1 :
INTRODUCTION TO PROCESS
DESIGN
1.1
1.2
OUTLINES
TYPES of piping and
instrumentation symbols.
How to CHOOSE the suitable
symbols in control system?
How to DEVELOP the piping
systems and the specification of the
process instrumentation,
equipment, piping, valves, fittings.
The ARRANGEMENT in P&ID
for the bioprocess plant design.
Block Flow
Diagram (BFD)
Process Flow
Diagram (PFD)
PROCESS
DIAGRAMS
Process equipments
symbol and
numbering
Piping and
Instrumentation
Diagram (P&ID)
Block Flow
Diagram (BFD)
Process Flow
Diagram (PFD)
PROCESS
DIAGRAMS
Process equipments
symbol and
numbering
Piping and
Instrumentation
Diagram (P&ID)
Toluene, C7H8
10,000 kg/hr
Reactor
Hydrogen
H2 820 kg/hr
C6H6
Gas Separator
CH4
C7H8
Benzene,
C6H6 8,210
kg/hr
Mixed
Liquid
75% Conversion
of Toluene
Reaction : C7H8 + H2
C6H6 + CH4
Example 2:
Production of Ethane from Ethanol
Ethanol is feed to continuous reactor with presence of Acid
Sulphuric catalyzer to produce ethylene. Distillation process then
will be applied to separate ethylene-H 2O 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.
CH3CH2O
H2=CH2 +
CH
H2
Answe
r:
H2SO4
Ni
Ethylene,
CH2CH2 (g)
CH2=CH2 +
H2O
CH
3CH3
Hot
water
out
Ethylene liq.
CH2CH2 (l)
Ethanol,
C2 H 5
OH
H
2SO4
Reactor 1
CH2C
HH
2 2O
Cold
water
Distillati
in
on
column
H2
O
Reactor 2
Hydroge
n, H2Ni
Ethane,
CH3CH3
Example 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 NH 3-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.
Water 5
L/min
Hot water
out
Insoluble
ammoni
a
Ammonia
liquid
Ammonia
gas
Absorber
Condenser
Batch
Distillation
Cold
water in
Ammonia-water
mixture
Ammonia-air mixture 10
L/min
Block Flow
Diagram (BFD)
Process Flow
Diagram (PFD)
PROCESS
DIAGRAMS
Process equipments
symbol and
numbering
Piping and
Instrumentation
Diagram (P&ID)
PROCESS
FLOW
DIAGRAM
(PFD)
A Process Flow Diagram generally includes
following information;
a)Flow rate of each stream in case of continuous
process or quality of each reactant in case of a batch
process.
b)Composition streams.
c)Operating conditions of each stream such as pressure
, temperature, concentration, etc.
d)Heat added or removed in a particular equipment.
e)Flows of utilities such as stream, cooling water,
brine, hot oil, chilled water, thermal fluid, etc.
f)Major equipment symbols, names and identification.
g)Any specific information which is useful in
understanding the process. For example, symbolic
presentation of a hazard, safety precautions, sequence
of flow, etc.
1. Major Pieces Of
Equipment
2. Utility
Streams
PFD
4. Basic
Control Loops
3. Process
Flow Streams
1. Major Pieces Of
Equipment
2. Utility
Streams
PFD
4. Basic
Control Loops
3. Process
Flow Streams
PFD will contains the following information:1. All major pieces of equipment (descriptive
name, unique equipment no.), pumps and valves.
2. All the utility streams supplied to major
equipments such as steam lines, compressed air
lines, electricity, etc.
Descriptio
n
Heat exchanger
H2O
Water cooler
Steam heater
Cooling coil
Descriptio
n
Heater coil
Centrifugal pump
Turbine type
compressor
Pressure gauge
Name
Description
Stripper
Absorber
Name
Description
Distillation
column
or
Liquid mixer
Name
Description
Reaction
chamber
Horizontal
tank
or cylinder
Name
Description
Boiler
Centrifuge
Name
Gate Valve
Globe
Valve
Ball Valve
Check Valve
Butterfly
Valve
Name
Relief Valve
Needle Valve
3-Way
Valve
Angle Valve
Butterfly
Valve
EXAMPLE 4
Production of Ethane from Ethanol
Ethanol 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.
H2SO4
CH3CH2OH
CH2=CH2 + H2
CH2=CH2 + H2O
CH3CH3
Ni
R-100
P-100
T-100
E-100
P-101
R-101
Reactor
Pump
Distillation
Column
Condenser
Pump
Reactor
Ethylen
e
CV-100
Ethanol
H2SO4
V100
R100
P100
VV101
102
V103
T100
E100
H2
Ethylene
liq.
V106
Hydrog
enNi
P-
R101
Ethane
EXAMPLE 5
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 NH 3 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.
T-100
T-101
E-100
Absorber Column
Batch Distillation
Column
Condenser
Insoluble
ammonia gas
Ammonia
gas
Water 5
L/min
Ammonia-air
mixture 10
L/min
Hot water
out
Ammonia
liquid
Cold water in
Ammonia-water
mixture
C - Compressor or Turbine
E - Heat Exchanger
H - Fired Heater
P - Pump
R - Reactor
T - Tower
TK - Storage Tank
V - Vessel
Supplemental Information
Ethylene
Cold
water in
Ethanol
Ethylene liq.
Cold
water
in
Ethanol
H2SO4
Hydrogen
Ni
H2O
P-100 A/B
Hot
water
out
Ethane
H2SO4
Hydrogen
Ni
H2O
P-100
A
P-100
B
In PFD
Ethylene liq.
In Real
Plant
Ethane
2. Utility
Streams
1. Major Pieces Of
Equipment
PFD
4. Basic
Control Loops
3. Process
Flow Streams
PFD will contains the following information:All process flow streams: identification by a
number, process condition, chemical composition.
Yes
No
No
EXAMPLE 4- CONT
R-100
P-100
T-100
E-100
P-101
R-101
Reactor
Pump
Distillation
Column
Condenser
Pump
Reactor
Hot
water
out
Ethylene liq.
Ethylene E-
100
V104
Cold
water inCV-101
T-100
CV-100
Ethanol
1
H2SO4
R100
V100
V101
V102
V105
V103
R101
8
7
P100
Hydroge
9
n Ni
V107
V106
H2O
P101
Ethane
10
300
8
6
10
600
24
12
11
4
24
Pressure
10.3
Mass
Flowrate
108
Molar
Flowrate
24
13
Gas
Flowrate
Liquid
Flowrate
EXAMPLE 4- CONT
R-100
P-100
T-100
E-100
P-101
R-101
Reactor
Pump
Distillation
Column
Condenser
Pump
Reactor
Hot water
out
Ethylene liq.
Ethylene E100
25
28
Cold
water
T-100
in
CV-100
Ethanol
H2SO4
R100
35
32.2
V100
V101
2
P100
V102
V104
V105
35
31.0
20
38
V103
V106
CV-101
Hydroge
n Ni
V107
R101
8
7
H2O
P101
Ethane
10
10
Temperature
(oC)
25.0
35.0
35.0
35.0
35.0
60.3
41
38
54.0
45.1
Pressure (psi)
28
32.2
31.0
31.0
30.2
45.1
31.3
24.0
39.0
2.6
Mass flow
(tonne/hr)
10.3
13.3
0.82
20.5
6.41
20.5
0.36
9.2
20.9
11.6
Mole flow
(kmol/hr)
108
114.2
301.0
1204.0
758.8
1204.4
42.6
1100.8
142.2
244.0
Vapor fraction
EXAMPLE 4- CONT
R-100
P-100
T-100
E-100
P-101
R-101
Reactor
Pump
Distillation
Column
Condense
r
Pump
Reactor
Hot water
out
Ethylene liq.
Ethylene E100
6
25
28
T100
CV-100
Ethanol
H2SO4 1
R100
35
32.2
Stream Number
V100
V101
2
P100
V102
V104
Cold
water in
V106
CV101
V105
20
38
V103
Hydroge
n Ni
V107
35
31.0
H 2O
Ethane
R101
10
P101
10
25.0
35.0
35.0
35.0
35.0
60.3
41
38
54
45.1
28
32.2
31.0
31.0
30.2
45.1
31.3
24.0
39
2.6
10.3
13.3
0.82
20.5
6.41
20.5
0.36
9.2
20.9
11.6
108
114.2
301.0
1204.0
758.8
1204.4
42.6
1100.8
142.2
244.0
Temperature (oC)
Pressure (psi)
Vapor fraction
1. Major Pieces Of
Equipment
2. Utility
Streams
PFD
4. Basic
Control Loops
3. Process
Flow Streams
PFD will contains the following information:- Basic control loops: showing the control
strategy used to operate the process under
normal operations.
EXAMPLE 4- CONT
R-100
P-100
T-100
E-100
P-101
R-101
Reactor
Pump
Distillation
Column
Condense
r
Pump
Reactor
Hot water
out
Ethylene liq.
Ethylene E100
V104
LIC
25
28
T100
CV-100
Ethanol
1
H2SO4
R100
35
32.2
Stream Number
V100
V101
4
3
2
P100
V102
Cold water
in
V106
CV101
V105
20
38
V103
V107
35
31.0
H 2O
Hydroge
n Ni
9
Ethane
R101
10
LIC
P101
10
25.0
35.0
35.0
35.0
35.0
60.3
41
38
54
45.1
28
32.2
31.0
31.0
30.2
45.1
31.3
24.0
39
2.6
10.3
13.3
0.82
20.5
6.41
20.5
0.36
9.2
20.9
11.6
108
114.2
301.0
1204.0
758.8
1204.4
42.6
1100.8
142.2
244.0
Temperature (oC)
Pressure (psi)
Vapor fraction
Block Flow
Diagram (BFD)
Process Flow
Diagram (PFD)
PROCESS
DIAGRAMS
Process equipments
symbol and
numbering
Piping and
Instrumentation
Diagram (P&ID)
Also
known
as
PROCESS
INSTRUMENTATION DIAGRAM
&
Common
synonyms
for
P&IDs
include
PFD
P&ID
Sensing Element
Final Control
Element
Measuring
Element
Transmitt
er
Transmit
Element
Control Element
Set point
Controller
Transmitte
r
Fluid
Fluid
Orifice
(Flow
Sensor)
Temperature
C
Ohms
-200
056
1.3
-100
0.32
0.8
0.12
0.3
100
0.30
0.8
200
0.48
1.3
300
0.64
1.8
400
0.79
2.3
500
0.93
2.8
600
1.06
3.3
650
1.13
3.6
FLOW
SENSOR
TRANSMITTER
Transmitter is a transducer* that responds to a
measurement variable and converts that input into a
standardized transmission signal.
*Transducer is a device that receives output signal from
sensors.
Pressure Level
Transmitter
Differential
Pressure
Transmitter
Pressure
Transmitter
CONTROLLER
the
Indicating Controller
Recording Controller
FINAL
CONTROL
Final Control Elementis a device that directly controls the
value of manipulated variable of control loop.
ELEMENT
Final control element may be control valves, pumps, heaters,
etc.
Pump
Control
Valve
Heater
Block Flow
Diagram (BFD)
Process Flow
Diagram (PFD)
PROCESS
DIAGRAMS
Process equipments
symbol and
numbering
Piping and
Instrumentation
Diagram (P&ID)
Field
mounted
on pipeline
Flow Controller
PT
FE
Pressure Transducer
FI
Flow Indicator
FT
Flow Transmitter
LC
FS
Flow Switch
Level Gauge
FIC
LR
FCV
Level Transmitter
FRC
LG
LT
Pressure Transmitter
Level Controller
LS
Level Recorder
Level Switch
Pressure Controller
LCV
PG
Pressure Gauge
LRC
PI
Pressure Indicator
PR
Pressure Recorder
TE
Temperature Element
Pressure Switch
TI
Temperature Indicator
PIC
Temperature Recorder
PCV
TS
PRC
Temperature Controller
PDI
Temperature Transmitter
PDR
PDS
PDT
Temperature
Switch
LV 100
LC
V-100
LT
LCV 101
Example 2
With
using
symbology;
PRV-100
PE
V-100
PIC
these
following
PE
Where PE is locally
mounted on V-100
PT
Where PT is locally
mounted
PIC
PT
CV-102
TK-102
(base feed tank)
TK-100
(pH adjustment
tank)
CV-101
pHE
1
pHT
1
pHE
2
pHT
2
pHIC
1
pHIC
2
pHIC
2
CV-102
TK-102
(base feed tank)
pHT
2
pHE
2
pHT
1
pHIC
1
pHE
1
TK-100
(pH adjustment
tank)
CV-101
pHE
1
pHT
1
pHTE
2
pHT
2
pHIC
1
pHIC
2
LT 1
FC
PCV100
L3
L2
TK-100
L1
FC
L5
PCV101
LIC 1
V-100
L4
LIC 2
FC
L3
PRV-100
L2
TK-100
LT 1
LT 1
L1
LIC 2
FC
PRV-101
LIC 1
L5
LT 2
V-100
L4
LT 2
LIC 2
Block Flow
Diagram (BFD)
Process Flow
Diagram (PFD)
PROCESS
DIAGRAMS
Process equipments
symbol and
numbering
Piping and
Instrumentation
Diagram (P&ID)
Instrumentation Numbering
XYY CZZLL
X represents a process variable to be measured.
(T=temperature, F=flow, P=pressure, L=level)
YY represents type of instruments.
C
Instrumentation Numbering
LIC 10003
L
IC
= Indicating controller.
100
03
= Loop number 3
Instrumentation Numbering
FRC 82516
F
RC
= Recording controller
825
16
= Loop number 16
Block Flow
Diagram (BFD)
Process Flow
Diagram (PFD)
PROCESS
DIAGRAMS
Process equipments
symbol and
numbering
Piping and
Instrumentation
Diagram (P&ID)
P&ID
PROCESS
CONTROL
VARIETY
Fluid in
LCV100
V-100
LT
V-100
Fluid
out
Fluid in
LCV100
V-100
LT
V-100
Fluid
out
V-100
TT
V 100
Fluid
out
FT
Fluid in
Y
Steam
LCV100
TI
Fluid out
Steam
LCV100
TI
Fluid out
FT
V-100
PI
FC
TC
FT
Fluid
in
TT
Steam
LCV-100
Fluid out
PIC
Y
PT
FC
FT
V-100
Hot steam
Water
BOILER
TIC
PIC
Y
TT
PT
Hot steam
Water
BOILER
FT
Wate
r
Acid
2 part of
water
1 part of
acid
Application:
with
with
specified physical properties.
- Maintaining correct air and fuel mixture to
combustion.
FIC
FF
FT
FT
Wate
r
Acid
2 part of
water
1 part of
acid
Remote Ratio
Adjustment
FT
Wate
r
AIC
Physical
Property
Measurement
2 part of
water
1 part of
acid
FT
Acid
Waste, pH 4.5
NaOH Tank
pH 6.5
pH Adjustment
Tank
pHC
FT
pHT
Waste, pH 4.5
NaOH Tank
pH 6.5
pH Adjustment
Tank
FC
FT
Valve A
Valve B
CV-102
pHIC
TK-102
(base feed tank)
pHT
1
TK-100
(pH adjustment
tank)
CV-101
TK-101
(acid feed tank)
ACTIVITY 1
(TECHNICAL REPORT)
THANK YOU