Chemical Process Diagrams: John Romar C. Panopio Che 413 Process Dynamics and Control

CHEMICAL PROCESS DIAGRAMS
JOHN ROMAR C. PANOPIO ● CHE 413 ● PROCESS DYNAMICS AND CONTROL

“The research and development group at ABC Chemicals
Company worked out a way to produce alpha-beta souptol (ABS).
Process engineers assigned to work with the development group
have pieced together a continuous process for making ABS in
commercial quantities and have tested key parts of it. This work
involved hundreds of block flow diagrams, some more complex
than others. Based on information derived from these block flow
diagrams, a decision was made to proceed with this process.
“A process engineering team from ABC’s central office carries
out the detailed process calculations, material and energy
balances, equipment sizing, etc. Working with their drafting
department, they produced a series of PFDs (Process Flow
Diagrams) for the process. As problems arise and are solved, the
team may revise and redraw the PFDs. Often the work requires
several rounds of drawing, checking, and revising.
Specialists in distillation, process control, kinetics, and heat

transfer are brought in to help the process team in key areas.
Some are company employees and others are consultants.
Since ABC is only a moderate-sized company, it does not have sufficient
staff to prepare the 120 P&IDs (Piping and Instrumentation Diagrams)
needed for the new ABS plant. ABC hires a well-known engineering and
construction firm (E&C Company), DEFCo, to do this work for them. The
company assigns two of the ABC process teams to work at DEFCo to
coordinate the job. DEFCo’s process engineers, specialists, and drafting
department prepare the P&IDs. They do much of the detailed engineering
(pipe sizes, valve specifications, etc.) as well as the actual drawing. The job
may take two to six months. Every drawing is reviewed by DEFCo’s project
team and by ABC’s team. If there are disagreements, the engineers and
specialists from the companies must resolve them.
Finally, all the PFDs and the P&IDs are completed and approved.
ABC can now go ahead with the construction. They may extend
their contract with DEFCo to include this phase, or they may go
out for construction bids from a number of sources.”
The most effective way of communicating information
about a process is through the use of flow diagrams.
1) Block Flow Diagram (BFD)
2) Process Flow Diagram (PFD)
TYPES OF 3) Piping and Instrumentation
CHEMICAL Diagram (P&ID)
PROCESS
DIAGRAMS
Complexity
Conceptual
increase
understanding
increase
BLOCK FLOW DIAGRAM DEFINITION
 A drawing of a chemical processes used

to simplify and understand the basic
structure of a system
 The diagram consisted of a series of
blocks representing different equipment
or unit operations that were connected by
input and output streams.
 Important information such as operating temperatures, pressures,

conversions, and yield was included on the diagram along with
flowrates and some chemical compositions.
BLOCK FLOW DIAGRAM EXAMPLE
 Production of Benzene
BLOCK FLOW DIAGRAM CONVENTION
 Operations/equipment are represented with
blocks
 Material flows are represented with straight lines
with arrows giving the direction of flow
 Lines are horizontal and/or vertical, with turns at
90 degree angles
 Flows go from left to right whenever possible
 If lines cross, the horizontal line is continuous and
the vertical line is broken
 Light streams (gases) are typically closer to the
top of the BFD than are heavy streams (liquids or
solids)
 Critical information unique to the process (such as
a chemical reaction) is supplied
 A simplified material balance should be provided
PROCESS FLOW DIAGRAM DEFINITION
 A critical component of process design.
 This diagram contains the bulk of the chemical engineering data necessary
for the design of a chemical process.
 It is necessary that chemical engineers know how to read process flow
diagrams because it is the primary method of detailing the process and
design information.
 The basic information provided by a PFD can be categorized into one of the
following:
1. Process topology
2. Stream information
3. Equipment information
PROCESS FLOW DIAGRAM PROCESS TOPOLOGY
 defined as the
interactions and
locations of the
different
equipment and
streams.
 It includes all of
the connections
between the
equipment and
how one stream is
changed to
another after it
flows through a
piece of
equipment.
 Equipment is
represented
symbolically by
“icons” that
identify specific
unit operations.
P-101 A/B
PROCESS FLOW DIAGRAM STREAM INFORMATION
 This shows the stream number, temperature,
pressure, vapor fraction, total mass flow rate, total
mole flow rate, individual component flow rates and
other physical properties. This is usually presented in
tables.
 The process streams is identified by a number in a
diamond box ◊ located on the stream.
 The direction of the stream is identified by one or
more arrowheads.
 Utility streams are also shown in PFD. Chemical plants
are provided with a range of central utilities that
include electricity, compressed air, cooling water,
steam, wastewater treatment, flares and etc.
PROCESS FLOW DIAGRAM EQUIPMENT INFORMATION
 This summary provides the
information necessary to
estimate the costs of equipment
and furnish the basis for the
detailed design of equipment.
PROCESS FLOW DIAGRAM EQUIPMENT INFORMATION
PIPING & INSTRUMENTATION DIAGRAM DEFINITION
 Also known as mechanical flow diagram (MFD)

 A diagram which shows the interconnection of Piping, Process
Equipment and the Instrumentation used to control the process.
 This also provides information needed by engineers to begin planning
for the construction of the plant.
 The last stage of process design and serves as a guide for those who
will be responsible for the final design and construction.
PIPING & INSTRUMENTATION DIAGRAM EXAMPLE
PIPING & INSTRUMENTATION DIAGRAM EXAMPLE
PIPING & INSTRUMENTATION DIAGRAM CONVENTION
PIPING & INSTRUMENTATION DIAGRAM CONVENTION
1) Block Flow Diagram (BFD)
2) Process Flow Diagram (PFD)
TYPES OF 3) Piping and Instrumentation
CHEMICAL Diagram (P&ID)
PROCESS
DIAGRAMS
Complexity
Conceptual
increase
understanding
increase
DEVELOPMENT OF PROCESS DIAGRAMS
CHEMICAL PROCESS DIAGRAMS
JOHN ROMAR C. PANOPIO ● CHE 413 ● PROCESS DYNAMICS AND CONTROL

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CHEMICAL PROCESS DIAGRAMS

JOHN ROMAR C. PANOPIO ● CHE 413 ● PROCESS DYNAMICS AND CONTROL

Specialists in distillation, process control, kinetics, and heat

 A drawing of a chemical processes used

 Important information such as operating temperatures, pressures,

 Also known as mechanical flow diagram (MFD)

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