Perpipaan
Universitas Sultan Agung
Tirtayasa
ACHMAD RIFAI
Block Flow Process Flow
Diagram (BFD) Diagram (PFD)
PROCESS
DIAGRAMS
Process equipments Piping and
symbol and Instrumentation
numbering Diagram (P&ID)
BLOCK FLOW DIAGRAM (BFD)
Is the simplest flowsheet.
Process engineer begins the process design with a block diagram in
which only the feed and product streams are identified.
Input-output diagrams are not very detailed and are most useful in
early stages of process development.
Flow of raw materials and products may be included on a BFD.
The processes described in the BFD, are then broken down into
basic functional elements such as reaction and separation sections.
Also identify the recycle streams and additional unit operations to
achieve the desired operating conditions.
BLOCK FLOW DIAGRAM (BFD)
Example 1:
Mixed Gas
Toluene, C7H8 2610 kg/hr
10,000 kg/hr
Reactor Gas Separator Benzene, C6H6
C6H6
8,210 kg/hr
CH4
Hydrogen H2
820 kg/hr C7H8
Mixed Liquid
75% Conversion of
Toluene
Reaction : C7H8 + H2 C6H6 + CH4
Figure 1: Block Flow Diagram for the Production of Benzene
Block Flow Process Flow
Diagram (BFD) Diagram (PFD)
PROCESS
DIAGRAMS
Process equipments Piping and
symbol and Instrumentation
numbering 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.
PROCESS FLOW DIAGRAM
1. Major Pieces Of 2. Utility
Equipment Streams
PFD
4. Basic Control 3. Process Flow
Loops Streams
PROCESS FLOW DIAGRAM (PFD)
1. Major Pieces Of 2. Utility
Equipment Streams
PFD
4. Basic Control 3. Process Flow
Loops Streams
PROCESS FLOW DIAGRAM (PFD)
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.
PROCESS FLOW DIAGRAM (PFD)
Process Unit Symbology
Symbol Description
Heat exchanger
H2 O Water cooler
S Steam heater
Cooling coil
PROCESS FLOW DIAGRAM (PFD)
Process Unit Symbology
Symbol Description
Heater coil
Centrifugal pump
Turbine type compressor
Pressure gauge
PROCESS FLOW DIAGRAM (PFD)
Process Unit Symbology
Symbol Name Description
Stripper A separator unit used
commonly to liquid mixture
into gas phase.
Absorber A separator unit used
commonly to extract mixture
gas into liquid phase.
PROCESS FLOW DIAGRAM (PFD)
Process Unit Symbology
Symbol Name Description
Distillation A separator unit used
commonly to crack liquid
column contains miscellaneous
component fractions.
Liquid mixer A process unit that used to
or
mix several components of
liquid.
PROCESS FLOW DIAGRAM (PFD)
Process Unit Symbology
Symbol Name Description
Reaction A process unit where chemical
process reaction occurs
chamber
Horizontal tank A unit to store liquid or gas.
or cylinder
PROCESS FLOW DIAGRAM (PFD)
Process Unit Symbology
Symbol Name Description
Boiler A unit for heating.
Centrifuge A separator unit that to
physically separated liquid
mixture. (exp: oil-liquid)
PROCESS FLOW DIAGRAM (PFD)
Valve Symbology
Symbol Name
Gate Valve
Globe Valve
Ball Valve
Check Valve
Butterfly Valve
PROCESS FLOW DIAGRAM (PFD)
Valve Symbology
Symbol Name
Relief Valve
Needle Valve
3-Way Valve
Angle Valve
Butterfly Valve
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 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.
T-100 T-101 E-100
Absorber Column Batch Distillation Column Condenser
Insoluble ammonia
gas Hot water out
Ammonia gas
Ammonia liquid
Water 5 L/min
Cold water in
Ammonia-air
mixture 10 L/min
Ammonia-water mixture
PROCESS FLOW DIAGRAM (PFD)
Process Unit Tagging and Numbering
Process Equipment General Format XX-YZZ A/B
XX are the identification letters for the equipment classification
C - Compressor or Turbine
E - Heat Exchanger
H - Fired Heater
P - Pump
R - Reactor
T - Tower
TK - Storage Tank
V - Vessel
Y - designates an area within the plant
ZZ - are the number designation for each item in an equipment class
A/B - identifies parallel units or backup units not shown on a PFD
Supplemental Information Additional description of equipment given on top of PFD
PROCESS FLOW DIAGRAM (PFD)
A/B Letter
Example
Hot water
out Hot water
out
Ethylene
Ethylene
Ethylene liq.
Cold
water in Cold Ethylene liq.
Ethanol water in
Ethanol
H2SO4 Hydrogen Ethane H2SO4 Hydrogen Ethane
Ni
Ni
H2O H2O
P-100 A/B P-100 A
P-100 B
In Real Plant
In PFD
1. Major Pieces Of 2. Utility
Equipment Streams
PFD
4. Basic Control 3. Process Flow
Loops Streams
PROCESS FLOW DIAGRAM (PFD)
PFD will contains the following information:-
All process flow streams: identification by a
number, process condition, chemical composition.
PROCESS FLOW DIAGRAM (PFD)
Stream Numbering and Drawing
- Number streams from left to right as much as possible.
- Horizontal lines are dominant.
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 E-100 Ethylene liq.
6
V-104
Cold water
T-100
in CV-101 V-106
CV-100
V-105
Ethanol 5
1 V-101 V-102
H2SO4
4 Hydrogen
V-100 9
V-103 V-107 Ni
R-100
R-101 Ethane
3 8
2 10
H2O
7
P-101
P-100
PROCESS FLOW DIAGRAM (PFD)
Stream Information
-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
PROCESS FLOW DIAGRAM (PFD)
Stream Information - Flag
600 Temperature
300
3 8 24 Pressure
9
6 7 Mass Flowrate
10.3
1 10
108 Molar Flowrate
600
24
2 5 12 Gas Flowrate
4 11 Liquid
Flowrate
24
13
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 E-100 Ethylene liq.
6
V-104
Cold
water in CV-101 V-106
25 CV-100
T-100
28 V-105
Ethanol 5 38 20
1 V-101 V-102
H2SO4 4 Hydrogen
V-100
V-103 Ni
9
V-107
R-100
Ethane
3 8
R-101
2 35 10
35 31.0 7
H2O
32.2 P-101
P-100
PROCESS FLOW DIAGRAM (PFD)
Stream Information - Full stream data:
Stream 1 2 3 4 5 6 7 8 9 10
Number
Temperature 25.0 35.0 35.0 35.0 35.0 60.3 41 38 54.0 45.1
(oC)
Pressure (psi) 28 32.2 31.0 31.0 30.2 45.1 31.3 24.0 39.0 2.6
Vapor fraction
Mass flow 10.3 13.3 0.82 20.5 6.41 20.5 0.36 9.2 20.9 11.6
(tonne/hr)
Mole flow 108 114.2 301.0 1204.0 758.8 1204.4 42.6 1100.8 142.2 244.0
(kmol/hr)
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 E-100 Ethylene liq.
6
V-104
Cold
water in V-106
25 CV-100
T-100
CV-101
28 V-105
Ethanol 5 20
H2SO4 1 V-101 V-102
4 38 Hydrogen
V-100
V-103 V-107 Ni
9
R-100
Ethane
3 8
R-101
2 35 10
35 31.0 7 H2O
32.2 P-101
P-100
Stream Number 1 2 3 4 5 6 7 8 9 10
Temperature (oC) 25.0 35.0 35.0 35.0 35.0 60.3 41 38 54 45.1
Pressure (psi) 28 32.2 31.0 31.0 30.2 45.1 31.3 24.0 39 2.6
Vapor fraction
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
1. Major Pieces Of 2. Utility
Equipment Streams
PFD
4. Basic Control 3. Process Flow
Loops Streams
PROCESS FLOW DIAGRAM (PFD)
PFD will contains the following information:-
- Basic control loops: showing the control
strategy used to operate the process under
normal operations.
E X A MP LE 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 E-100 Ethylene liq.
6
V-104
Cold water in
LIC V-106
25 CV-100
T-100
CV-101
28 V-105
Ethanol 5 20
H2SO4
1 V-101 V-102
4 38 Hydrogen
V-100
V-103 Ni
9
R-100 V-107
Ethane
3 8
R-101
2 35 10
35 31.0 7 H2O
32.2 P-101 LIC
P-100
Stream Number 1 2 3 4 5 6 7 8 9 10
Temperature (oC) 25.0 35.0 35.0 35.0 35.0 60.3 41 38 54 45.1
Pressure (psi) 28 32.2 31.0 31.0 30.2 45.1 31.3 24.0 39 2.6
Vapor fraction
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
R-100 P-100 T-100 E-100 P-101 R-101
Reactor Pump Distillation Column Condenser Pump Reactor
Hot water out
Ethylene E-100 Ethylene liq.
6
V-104
Cold water in
LIC V-106
25 T-100
CV-100 CV-101
28
V-105
Ethanol 5 20
1 V-101 V-102
H2SO4 4 38 Hydrogen
V-100 9
V-103 V-107 Ni
R-100
3 R-101 Ethane
2 8 10
35
35 31.0 7 H2O
32.2 P-101 LIC
P-100
Stream Number 1 2 3 4 5 6 7 8 9 10
Temperature (oC) 25.0 35.0 35.0 35.0 35.0 60.3 41 38 54 45.1
Pressure (psi) 28 32.2 31.0 31.0 30.2 45.1 31.3 24.0 39 2.6
Vapor fraction
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
