Chemical Process Design and

Economics (CPDE)
6th Semester,
B.Sc. Chemical Engineering

Delivered by:
Dr Usman Ali

Department of Chemical Engineering

University of Engineering & Technology, Lahore
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 developing the necessary
computer aided design (CAD) and process drawings. 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 other companies.
Chemical Process Diagrams
 3 Levels of Diagram
❑Block Flow Diagram (BFD)
❑Process Flow Diagram (PFD)
❑Piping and Instrumentation Diagram (P&ID) – often
referred to as Mechanical Flow Diagram
Complexity Conceptual
increases understanding
increases
As chemical engineers, we are most familiar with BFD
and PFD.
 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 –
engineering information is missing
 Block Flow Process
Diagram
• Similar to sketches in
material and energy
Definitions balances
of BFD
Block Flow Plant
Diagram
• Gives a general view of a
large complex plant
Block Flow Process Diagram
 Developing a Process

❖ Target product is 37% formaldehyde in water.

Known as formalin
❖ Occurs of a silver catalyst at 200 oC and 2 – 3
atm pressure
❖ Reaction 1 is the predominant reaction
❖ Develop a block flow diagram that describes the
process
❖ B.P. Pure formaldehyde = -19.3 oC
B.P. Formalin = 96 oC
Block Flow Plant Diagram
Process Flow Diagram

❑PFD shows all process

engineering information
– Diagram developed in CPI
(especially the 2nd/3rd
semester)
– Often PFD is drawn on large
paper
 Process Flow Diagram

❑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
Process Flow Diagram
 Process Flow Diagram
Table 1.2 : Conventions Used for Identifying Process Equipment
General Format XX-YZZ A/B
Process Equipment 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

Supplemental Y designates an area within the plant

Information 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
Additional description of equipment given on top of PFD
 XX-YZZ A/B/…
➢XX represents a 1- or 2-
letter designation for the
equipment (P = pump)
➢Y is the 1 or 2 digit unit
Equipment number (1-99)
Numbering ➢ZZ designates the
equipment number for the
unit (1-99)
➢A/B/… represents the
presence of spare
equipment
 Thus, T-905 is the 5th tower in
unit nine hundred P-301 A/B is
the 1st Pump in unit three
hundred plus a spare
• Use unambiguous letters for
new equipment
Equipment – Ex. Turbine use Tb or J not T
Numbering (used for tower)
– Replace old vessel V-302
with a new one of different
design - use V-319 (e.g.) not
V-302 – since it may be
confused with original V-302
 Stream Numbering and Drawing
• Number streams from left to right as much as
possible
• Horizontal lines are dominant

yes no no
 Stream Numbering
and Drawing
❑ Add arrows for
– Change in direction
– Inlet of equipment
❑ Utility streams should use
conventions lps, cw, fg, etc.
 Stream
Information
❑ Since diagrams are small, not
much stream information can
be included
❑ Include important data –
around reactors and towers,
etc.
– Flags are used – see
toluene HDA diagram
– Full stream data indicated
in a separate flow
summary table
Stream Information - Flags
 Process Flow Diagram
Information 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/h)
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
 Process Flow Diagram
A Portion of Table 1.5
Stream Number 1 2 3 4 5 6 7 8 9 10

Temperature (°C) 25 59 25 225 41 600 41 38 654 90

Pressure (bar) 1.90 25.8 25.5 25.2 25.5 25.0 25.5 23.9 24.0 2.6

Vapor Fraction 0.0 0.0 1.00 1.0 1.0 1.0 1.0 1.0 1.0 0.0

Mass Flow (tonne/h) 10.0 13.3 0.82 20.5 6.41 20.5 0.36 9.2 20.9 11.6

Mole Flow (kmol/h) 108.7 144.2 301.0 1204.4 758.8 1204.4 42.6 1100.8 1247.0 142.2

Component Mole Flow

(kmol/h)

Hydrogen 0.0 0.0 286.0 735.4 449.4 735.4 25.2 651.9 652.6 0.02

Methane 0.0 0.0 15.0 317.3 302.2 317.3 16.95 438.3 442.3 0.88

Benzene 0.0 1.0 0.0 7.6 6.6 7.6 0.37 9.55 116.0 106.3

Toluene 108.7 143.2 0.0 144.0 0.7 144.0 0.04 1.05 36.0 35.0
Basic Control
Loops
Often the basic control
loops (those involving
maintaining material
balance and reactor
controls) are included on
the PFD; instrumentation
and other control loops
are not shown
Basic Control Loops
 Equipment are identified
by number and a label
(name) positioned above
the equipment on the PFD
Equipment
Information Basic data such as size and
key data are included in a
separate table (Equipment
Summary Table)
 Vessel V-101 V-102
Temperature 55 38
Equipment (ºC)
Information Pressure (bar) 2.0 24
Orientation Horizontal Vertical
MOC CS CS
Size
Height/Length 5.9 3.5
(m)
Diameter (m) 1.9 1.1
Internals s.p. (splash
plate)
 P&ID –
Construction Bible
Piping and • Contains: plant
Instrument construction
Diagram(P&ID) information (piping,
process,
instrumentation, and
other diagrams)
P&ID
 V-102 contains an LE (Level
Element)

LE senses liquid level in separator

and adjusts flow rate leaving
Look at V-102
on P&ID LE opens and closes a valve
depending on liquid level

LE and valve represent a

feedback control loop
 Plot Plans – plan or map
drawn looking down on
plant (drawn to scale with
all major equipment
Other identified)
Common
Elevation Diagrams – show
Diagrams view from side and give
information about
equipments distance from
ground
Other Common Diagrams

Section of Plot Plan Section of Elevation Diagram

 Piping Isometrics – show
Other piping in 3-dimensions
Common
Diagrams Vessel Sketches – show key
dimensions of equipment
and locations of inlet and
outlet nozzles etc.
 Scale Models and
Virtual Plants

❑ 25 years ago physical models were used for review

❑ Now virtual or electronic models are generated using
software (3-d plant diagrams)
❑ Purpose of Models – catch errors such as
– Piping clashes
– Misaligned piping
– Equipment not easily accessed
– Sample points not easily reached by operators
3-D Plant
Diagrams
The Structure and
Synthesis of Process
Flow Diagrams
Generic Structure of Process Flow Diagrams
Generic Structure of Process Flow Diagrams
Generic Structure of Process Flow Diagrams
 Environmental Control

End of Pipe vs. Green Approach

• Most significant changes obtained by changing process chemistry within

reactor – eliminate/minimize unwanted by-products

End of Pipe vs. Common Units

• Fired Heaters - excess oxygen

• low sulfur fuel
• NOX control
• Wastewater- biological/sedimentation/
• - filtration
Approach of Douglas*
Five step process to tackle a conceptual
process design
• Batch vs. continuous
• Input-output structure
• Identify and define recycle
structure of process
• Identify and design general
structure of separation
system
• Identify and design heat-
exchanger network or process
energy recovery system
*Douglas, J.M., Conceptual Design of Chemical Processes, McGraw-
Hill, NY, 1988
Batch vs.
Continuous

• Variables to Consider:
• Size
• Batch < 500 tonne/yr ~ 1.5 tonne/day (<
2 m3 of liquid or solid per day)
• Continuous > 5000 tonne/yr
Batch vs. Continuous
Batch vs. Continuous

✓ Continuous allows the process to benefit from

the “Economy of Scale,” but the price is less
flexibility
Batch vs. Continuous

✓ Other Issues
❖ Accountability and quality control – FDA requires
batch accountability
❖ Safety – batch is more accident prone
❖ Scheduling of equipment – may be most
important issue
❖ Seasonal demands – e.g., antifreeze, food
products
 Input – Output Structure
(Process Concept Diagram)
 Input – Output Structure
(Process Concept Diagram)
 Input – Output Structure
(Process Concept Diagram)
 Other Input – Output Issues
Purify Feed ?
✓Feed purity and trace components
✓Small quantities and “inerts” – do not separate

Example H2 in feed contains CH4

CH4 does not react
so – do not remove
Other Input – Output
Issues
• If separation of impurities is
difficult – Do not separate
• Azeotrope – (water and
ethanol)
• Gases – (requires high P
and low T)

• How would you remove CH4

from H2?
Other Input – Output
Issues
• If impurities foul or poison catalyst
then separate
• Sulfur – Group VIII Metals (Pt,
Pd, Ru, Rh)
• CO in platinum PEM fuel cells
• Note: S and CO may be present
in very small amounts (ppm)
 Other Input – Output Issues
❑ If impurity reacts to form difficult-to-
separate material or hazardous product then
separate
Phosgene Example
CH4 + H2O CO + 3H2
CO + Cl2 COCl2
Any H2 HCl
Other Input –
Output Issues
✓ Impurity in large
quantities then purify –
why?

A notable exception is air

Add Materials to
Feed
• Stabilize products
• Enable
separation/minimize side
reactions
• Anti-oxidants and
scavengers
• Solvents and catalysts
 Inert Feeds

Control exothermic reactions

▪ Steam for oxidation reactions (explosion limits)
▪ Reduces coke formation on catalyst
Control equilibrium
▪ Adding inerts shifts equilibrium to the right
e.g., styrene reaction

C6H5CH2CH3 C6H5CHCH2 + H2
 Profit Margin
If $ Products - $ Raw Material < 0,
then do not bother to pursue this
process, but start looking for an
alternate route
Toluene HDA vs. Toluene Disproportionation

C6H5CH3 + H2 →C6H6 + CH4

Toluene benzene
Toluene used more
efficiently
2C6H5CH3 →C6H6 +C6H4(CH3)2
Toluene benzene xylene
 ❑ Since raw materials make up
from 25 to 75% of total
operating costs, should recover
as much raw material as
possible
Recycle • Exception is when raw
materials are very cheap

For example, Air Separation

 3 Basic Recycle Structures
Separate and purify unreacted feed from products and then recycle, e.g.,
toluene

Recycle feed and products together and use a purge stream, e.g.,
hydrogen with purge as fuel gas

Recycle feed and products together but do not use a purge stream - must
come to Equilibrium

2C6H6 C12H10 + H2
Recycle Structure in PFD
Recycle without separation or
purge

Recycle
increases and
equip. and op.
costs increase

2C6H6 C12H10 + H2
Recycle with Separation (and
Purge) 2C6H6 C12H10 + H2

Extra tower
with associated
operating costs
Other Issues on
Recycle

• Number of recycle streams

• Does excess reactant affect
structure
• Size of Recycle Loop H2 :
Toluene = 5 : 1
• Number of Reactors
• Separate and recycle to
different reactors
Other Issues
on Recycle
• Do we need to purify
prior to recycling?
• Is recycling of inerts
warranted?
• Can recycling an
unwanted inert
material push
equilibrium to the
right?
• – Gasification of coal –
CO2 recycle
Other Issues on
Recycle

✓ Can recycling an
unwanted inert control
reaction
CO2 in Gasifier
✓ Phase of Recycle Stream?
 References

Turton, R.; Bailie, R. C.; Whiting, W. B.;

Shaeiwitz, J. A.; Bhattacharyya, D., Analysis,
Synthesis, and Design of Chemical Processes.
4th Edition; Pearson Education, 2012.

✓ Chapter 1 & Chapter 2