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Chemical Process System Design

This document provides information on chemical process design, including process diagrams and conventions. It discusses block flow diagrams, process flow diagrams, and piping and instrumentation diagrams. Tables are included that outline the conventions and standards for labeling equipment, streams, and other elements in process diagrams. The purpose of process diagrams is to effectively communicate information about a chemical process.

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0% found this document useful (0 votes)
121 views29 pages

Chemical Process System Design

This document provides information on chemical process design, including process diagrams and conventions. It discusses block flow diagrams, process flow diagrams, and piping and instrumentation diagrams. Tables are included that outline the conventions and standards for labeling equipment, streams, and other elements in process diagrams. The purpose of process diagrams is to effectively communicate information about a chemical process.

Uploaded by

Nguyễn An
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Chemical Process System

Design

Introduction
THE NATURE OF PROCESS DESIGN

A Creative Activity !

[ Example ]

CH3

+ H2 + CH4

Toluene Hydrogen Benzene Methane


The most effective way of
communicating information about
a process is through the use of
flow diagrams.
• Block Flow Diagram (BFD)
• Process Flow Diagram (PFD)
• Piping and Instrumentation Diagram (P&ID)
Toluene Mixed Gas
(10,000 kg/h) (2,610 kg/h)
Reactor Gas
Separator
Benzene
Hydrogen (8,210 kg/h)
(820 kg/h) Conversion Mixed Liquids
75% Toluene

Toluene

Reaction : C7H8 + H2 = C6H6 + CH4

Figure 1.1 Block flow process diagram for the production of benzene
Toluene and hydrogen are converted in a reactor to produce benzene and methane. The
reaction does not go to completion, and excess toluene is required. The noncondensable
gases are separated and discharged. The benzene product and the unreacted toluene are
then separated by distillation. The toluene is then recycled back to the reactor and the
benzene removed in the product stream.
Table 1.1 Conventions and Format Recommended for Laying out a
Block Flow Process Diagram

1. Operations shown by blocks.


2. Major flow lines shown with arrows giving direction of flow.
3. Flow goes from left to right whenever possible.
4. Light stream (gases) toward top with heavy stream (liquids and solids) toward
bottom.
5. Critical information unique to process supplied.
6. If lines cross, then the horizontal line is continuous and the vertical line is broken.
7. Simplified material balance provided.
Process Flow Diagram (PFD)

A PFD includes the following items:

1. major equipment;
2. principal flow route and control involved from raw
material feed to final product;
3. key temperature and pressure corresponding to
anticipated normal operation;
4. material flow rates and compositions;
5. design duties and sizes of major equipment.
Table 1.2 Conventions Used for Identifying Process Equipment

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
Table 1.3 Conventions for Identifying Process and Utility Streams
Process Streams
All conventions shown in Table 1.1 apply.
Diamond (square) symbol located in flow lines.
Numerical identification (unique for that stream) inserted in diamond (square).
Flow direction shown by arrows on flow lines.
Utility Streams
lps Low Pressure Steam: 3-5 barg (sat)‡
mps Medium Pressure Steam: 10-15 barg (sat)‡
hps High Pressure Steam: 40-50 barg (sat)‡
htm Heat Transfer Media (Organic): to 400C
cw Cooling Water: From cooling tower 30C returned at less than 45C+
wr River Water: From river 25C returned at less than 35C
rw Refrigerated Water: In at 5C returned at less than 15C
rb Refrigerated Brine: In at -45C returned at less than 0C
cs Chemical Waste Water with high COD
ss Sanitary Waste Water with high BOD, etc.
el Electric Heat (specify 220, 440, 660V service)
ng Natural Gas
fg Fuel Gas
fo Fuel Oil
fw Fuel Water
‡Thesepressure are set during the preliminary design stages and typical values vary within the ranges
shown.
+Above 45C, significant scaling occurs.
Table 1.4 Information Provided in a Flow Summary
Essential Information
Stream Number
Temperature (C)
Pressure (bar)
Vapor Fraction
Total Mass Flow Rate (kg/h)
Total Mole Flow Rate (kmol/h)
Individual Component Flow Rates (kmol/s)
Optional Information
Component Mole Fractions
Component Mass Fractions
Individual Component Flow Rates (kg/h)
Volumetric Flow Rates (m3/h)
Significant Physical Properties
Density
Viscosity
Other
Thermodynamic Data
Heat Capacity
Stream Enthalpy
K-values
Stream Name
Table 1.6 Equipment Descriptions for PFD and P&IDs
Equipment Type
Description of Equipment
Towers
Size (height and diameter), Pressure, Temperature
Number and Type of Trays
Height and Type of Packing
Materials of Constructions
Heat Exchangers
Type: Gas-Gas, Gas-Liquid, Liquid-Liquid, Condenser, Vaporizer
Process: Duty, Area, Temperature, and Pressure for both streams.
No. of shell and Tube Passes
Materials of Construction: Tubes and Shell
Tanks
See vessels
Vessels
Hight, Diameter, Orientation, Pressure, Temperature, Materials of Construction
Pumps
Flow, Discharge Pressure, Temperature, P, Driver Type, Shaft Power, Materials of Construction
Compressors
Actual Inlet Flow Rate, Temperature, Pressure, DrverType, Shaft Power,
Materials of Construction
Heaters (fired)
Type, Tube Pressure, Tube Temperature, Duty, Fuel, Material of Construction
Others
Provide Critical Information
Piping and Instrumentation Diagram
(P&ID)
1. All process equipments and pipings required for start-up, shut-down, emergency and
normal operation of the plant, including valves, blinds, etc.
2. An id number, an identifier of the material of construction, diameter and insulation
requirements for each line.
3. Direction of flow.
4. Identification of main process and start-up lines.
5. All instrumentation, control and interlock facilities with indication of action on
instrument air failure.
6. Key dimensions or duties of all equipments.
7. Operating and design pressures and temperatures for vessels and reactors.
8. Equipment elevations.
9. Set pressure for relief valves.
10.Drainage requirements.
11.Special notes on piping configuration as necessary, e.g. “gravity drainage.”
Table 1.8 Exclusions from Piping and Instrumentation Diagram

1. Operating conditions T,P


2. Stream flows
3. Equipment locations
4. Pipe routing
a. Pipe lengths
b. Pipe fittings
5. Supports, structures, and foundations
Table 1.9 Conventions in Constructing Piping and Instrumentation Diagrams
For Equipment - Shown Every Piece Including
Spare units
Parallel units
Summary details of each unit
For Piping - Include All Lines Including Drains, Sample Connections and Specify
Size (use standard sizes)
Schedule (thickness)
Materials of construction
Insulation (thickness and type)
For Instruments - Identify
Indicators
Recorders
Controllers
Show instrument lines
For Utility - Indentify
Entrance utilities
Exit utilities
Exit to waste treatment facilities
Activities of Process Design
(1)Synthesis
The step where one conjectures the building blocks and their
interconnections to create a structure which can meet the stated design
requirements.
(2)Analysis (Simulation)
The activity of modeling and then solving the resulting equations to
predict how a selected structure should behave if it were constructed.
(3)Evaluation
The activity of placing a worth on the structure where the worth might
be its cost, its safety, or its net energy consumption.
(4)Optimization
The systematic searching over the allowed operating conditions to
improve the evaluation as much as possible.

Parameter
structure
Process Synthesis
A design task where one conjectures the
building blocks and their interconnections to
create a structure which can meet the stated
design requirements.
IMPORTANCE OF PROCESS STRUCTURE
(1) Recycle? A→P
R or R S
A P A
                    P

(2)separation Sequence ?
A (propane) B (1-Butene) C(n-Butane)
A B A

AB
or
ABC ABC

C B
BC C
C

(3)Heat Recovery ?

or
H
Feed Product
Streams PROCESS ? Streams

(a) Process design starts with the synthesis of a process to convert raw
materials into desired products.

Feed Product
Streams PROCESS Streams ?

(b) Simulation predicts how a process would behave if it was constructed.

Figure 1.1 Synthesis is the creation of a process to transform feed streams


into product streams. Simulation predicts how it would behave if it was
constructed.
Figure 1.6 The “onion model” of
process design. A reactor design in
Reactor needed before the separation and recycle
system can be designed, and so on.
(From Smith and Linnhoff, Trans.
Separation and
Recycle System IChemE, ChERD, 66:195, 1988;
reproduced by permission of the
Heat Exchanger Institution of Chemical Engineers.)
Network
Utilities
Example Hydrodealkylation of Toluene
CH3

1 + H2 + CH4

Toluene Benzene

2 + H2

Benzene Diphenyl
A HIERARCHICAL APPROACH

Toluene + H2  Benzene + CH4


2 Benzene Diphenyl + H2
1150  F ~ 1300  F
500 psia
Liquid
recycle
Benzene
product
H2, CH4
Purge

compressor
Gas
Diphenyl
recycle

furnace Reactor Flash


hh
CW

H2, feed
FIGURE 1.2-2
Hydrodealkylation of toluene; maximum energy recovery. Toluene
feed

ENERGY INTEGRATION
Vapor Recovery System

H2 Feed Purge
compressor

Reactor Flash
Toluene
Drum
Feed
Benzene

Toluene
Recycle

Benzene Col.
Toluene Col.

Stablizer
Diphenyl

Distillation Train
ALTERNATIVES OF DISTILLATION TRAIN
(1) Recycle Diphenyl
H2, CH4 Benzene

(2)
Feed
Toluene
(recycle)

Diphenyl

(3)
H2
CH4 Benzene Toluene
(recycle)

Diphenyl
ALTERNATIVES OF VAPOR RECOVERY
SYSTEM

(1) Condensation;
(2) Absorption;
(3) Adsorption;
(4) Membrane.
Vapor recovery Purge
system H2 , CH4

H2 , CH4
Reactor Phase
system split
Toluene

Benzene
Liquid separation
system
Dipheny1

Simplified Flowsheet for the Separation System


Gas recycle Purge
H2 , CH4

Benzene
H2 , CH4 Reactor Separation
Toluene system system
Dipheny1

Toluene recycle

Recycle Structure of the Flowsheet


Purge
H2 , CH4

H2 , CH4 Benzene
Toluene Dipheny1

Input-Output Structure of the Flowsheet


Hierarchy of decisions
1. Batch versus continuous
2. Input-output structure of the flowsheet
Ch. 4
3. Recycle structure of the flowsheet
4. General structure of the separation system Ch.5

a. Vapor recovery system


b. Liquid recovery system
5. Heat-exchanger network Ch.6, Ch.7, Ch.16

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