INTRODUCTION TO PROCESS PLANT

DESIGN

Khashayar Saleh

Professeur des universités

Technologies des poudres et
suspensions
Dépt. Génie des Procédés
Industriels

Sorbonne Universités
Université de Technologie
de Compiègne

E-mail : [email protected]
Tel. +33 (0)3.44.23.52.74

Prof. K. SALEH
[email protected]
Chemical Engineering Dept.
Sorbonne Universités/Université de Technologie de Compiègne
 The role of chemical/process engineer

 Engineers Conceive, Design, Implement, and Operate (CDIO) engineering solutions

PE

2
 A chemical engineer is someone who knows enough physics
to confuse a chemist, enough chemistry to confuse a physicist
UV TA02
& enough mathematics to confuse themselves.

•INTRODUCTION

• CONTEXTE & ENJEUX

•PROJECT MANAGEMENT

•CONCEPTUAL DESIGN

•ECONOMICAL ANALYSIS

•ORGANISATION & AGENDA

3
 Introduction
 Chemical Engineer1:
UV TA02 According to « Institution of Chemical Engineering »:

"That branch of engineering, which is concerned with

•INTRODUCTION processes, which change the chemical composition or
• CONTEXTE & ENJEUX
physical properties of material in bulk"
•PROJECT MANAGEMENT
 Steps of "Process plant design" 1
•CONCEPTUAL DESIGN
o Process development : the translation of the bench scale chemistry
•ECONOMICAL ANALYSIS
into a means whereby the material can be produced in a large scale
•ORGANISATION & AGENDA
o Heat & Mass Balances : Normally, the calculation is made backward
(i.e. from the desired production rate of the finished material)

o Plant design: design of major items of equipment on the plant

o Costing: the final stage in the specification of a plant design and the
most significant (total cost per unit mass of product as accurately as
is feasible in a reasonable time)

4 1 Source : Process Plant design, Backhurst & Harker

 The role of chemical/process engineer

 How to design/conduct the process to obtain the desired products/properties at a

lower cost while fully respecting environmental and safety regulations?

Procédés solides divisés

Modèles
Global globaux
models

Elementary
Mécanismes mechansims
élémentaires

- fluid mechanics
Lois cinétiques :
- -Transfert
hydrodynamics
de chaleur
Technologies
Technology - -Transfert
heat transfer
de matière
- -Réaction
mass transfer
chimique

Conditions opératoires - kinetics

Hydrodynamique - Propriétés
End-used’usage
properties
Operating conditions
- Chem. Rxn.solide
- circulation Eng. - Coût
purity
- Numerical tools
- circulation fluide - Environnement
cost
- …
- modélisation ou simulation - Risques,
Safety …
- …

Matières
Raw Premières
materials

5
Simplified steps of an industrial project

6
 Project life cycle for process plants (1/2)

 Different steps
o Identify/define the problem, need or demand (Basis of Design or BOD)
o Generate options that provide potential solutions to the problem
o Review the options against predetermined selection criteria and eliminate those options
that clearly do not satisfy the selction criteria
o Generate the conceptual process design for the selected options
o Front-End Engineering Design (FEED) studies
• work at laboratory scale to provide more data
• evaluate the possible locations, project timescale and order of magnitude of cost (CAPEX ∓10%)
• Develop the business case at the strategic level
• Determine regulatory requirements for product/process

o Reduce the number of options to those carried forward to the next level of detail
o Detailed design (P&ID, PDS, CAPEX ∓5%)
o Select the lead option to be designed and installed

7
 Project life cycle for process plants (2/2)

 Different steps (continued)

o Design for construction

o Construct the required infrastructure, utilities, piping, instrumentation, buildings, etc., and
install the required equipment

o Qualify/commission the equipment.

o Commission the process for validation. Verify that the plant performs as designed and
produces product of the required quality;

o Routine production keeping a close watch on quality consistency and output

o Improve/optimize the process efficiency based on data and experience gained during
routine production

o Decommission the plant at the end of the project life cycle

8
 Capital Expenditures (CAPEX) & Operating Expenses (OPEX)

 CAPEX  OPEX
Corresponds to purchases of significant Costs a company incurs for running its
goods or services in the future. CAPEX day-to-day operations.
are typically for fixed assets like
property, plant, and equipment (PP&E). Examples:
o Raw materials
Examples: o chemicals & catalysts
o Manufacturing plants, o Rent and utilities
o Equipments and machinery o Wages and salaries
o Laboratory o Accounting and legal fees
o Building improvements o Overhead costs such as selling, general &
o Computers administrative expenses (SG&A)
o Vehicles and trucks if bought o Property taxes
o Business travel
o piping and instrumentation
o Interest paid on debt
o Installation of equipments
o Etc.
o Etc.

9
 Different steps of an industrial process (1/4)

 Engineers conceive, design, implement, and

operate (CDIO) engineering solutions

 Different tasks of the feasibility phase

o Conceptual Design
o Basis of design (B.O.D)
o Block Flow Diagram (BFD)
o Selection of process diagrams
o Process Flow Diagram (PFD)
o Process modeling (simulations)
o Material and thermal balances
o Equipment specification (Process Data Sheet)
o Piping & Instrumentation Diagram (P&ID)

10
 Different steps of an industrial process (2/4)

Objectives
Assessment of profitability (market analysis) and technical feasibility 
to make the decision to launch a project

Delivered Items
Basis Of Design (unit capacity, power supplies, product specifications,
availability of utilities, sizing considerations, …)
11
 Typical engineering project phases – Process engineer activities / xx

CAPEX/OPEX evaluation

Basis of Design definition

Block flow diagrams
Schemes comparisons studies
Selection of licensors

Conceptual
or Feasibility

3 MONTHS
12
 / xx
Basis Of Design (BOD): example

 PLANT: Gas treatment

 CAPACITY: 1000 MMSCFD
 CHARGE:
 PRESSURE 60 – 80 barg
 TEMPERATURE: 20 – 30°C
 COMPOSITION
 N2 1%
 CO2 5%
 H2S 10%
 H2O 2%
 C1 65%
 C2 8%
 C3 4%
 iC4 2%
 nC4 1.5%
 nC5 0.5%
 iC5 0.5%
 C6+ 0.5%

13
 / xx

Basis Of Design (BOD): example

 DRY GAS
 Water content < 2lb/MMSCF
 Higher Heating Value < 1150 btu/SCF max
 Hydrocarbon dew Point < 10°C at 50 barg
 CO2 Content < 3%
 Sulfur Content < 28 ppm

 STABILIZED CONDENSATE
 Water content < 0.1 % (mass)
 RVP < 0.65 bara
 Sulfur Content <10 ppm

 SULFUR
 Recovery > 99.9%

14
 Different steps of an industrial process (3/4)

Objectives
Provide a general idea of the process, formulation and pre-selection of
alternatives, definition of the technology to be used

Delivered Items
Block diagrams, material and energy balances, operating conditions on the
main process currents, yields/equipment specifications
15
 Block Flow Diagram (BFD)

 BFD: Example: Biofuels of 2nd generation

• Differentes alternatives
o the simplest form of the flow
diagrams used in industry.

• a drawing of a chemical processes

used to simplify and understand the
basic structure of a system • Chemistry

• can represent anything from a single

piece of equipment to an entire plant • Block Flow Diagram (BFD)

Biomass Synthesis Separation

Raw Prod.
• used to break up a complicated materials
preparation reaction &
rectification
system into more reasonable
principle stages/sectors Recycle

16
 Conceptual or feasibility studies / xx

• Define the best process scheme to meet client expectations (Basis of Design)
• Example in Refining: optimize refining process scheme (master planning) to maximise revenues from product selling
• Tools: linear programming, « in-house » database and expertise

Hydrogen H2 Amine SRU Sulphur

NG Plant Fuel Gas
H2 C3
LPG
Isom. C3=
H2 C4
Naphtha + DIH
HDT
Catalytic H2
U 91 MTBE
Reformer
U 95 Gasoline
Crude U 98
Kero.
Crude Distillation Sweetening Jet
Unit
H2 Gasoil Diesel
HDS H. Oil

Vacuum H2
Distillation Hydrocracker
Unit Unc. Oil

Delayed
Coker

Coke
 Conceptual or feasibility studies / xx

Define the best process scheme to meet client expectations (Basis of Design)
• Example in Refining: optimize refining process scheme (master planning) to
maximise revenues from product selling
• Tools: linear programming, « in-house » database and expertise

Hydrogen H2 Amine SRU Sulphur

NG Plant Fuel Gas
H2 C3
LPG
Isom. C3=
H2 C4
Naphtha + DIH
HDT
Catalytic H2
U 91 MTBE
Reformer
U 95 Gasoline
Crude U 98
Kero.
Distillation Jet
Crude Sweetening
Unit
H2 Gasoil Diesel
HDS H. Oil

Vacuum H2
Distillation Hydrocracker
Unit Unc. Oil

Delayed
Coker

Coke
 Different steps of an industrial process (3/4)

Preliminary
Objective: to have an idea of all the dimensioning elements on the operation and
performance of the process
Delivered element: PFD, economic analyzes, security, environment, consumption.

Detailed
Objective: provide all the elements for construction and operation
Delivered element: hydraulic, civil engineering, mechanical, electrical layout diagrams,
instrumentation, control, …
19
 Typical engineering project phases / xx

CAPEX ±30%
FEED launching decision

CAPEX/OPEX evaluation

Process flow diagrams

Heat and Mass balances
Optimisations

Conceptual Pre-FEED /
or Feasibility “Basic”

3 MONTHS 6 MONTHS
 Development of a process scheme / xx

• Detailed Definition of the optimized scheme (at equipment

level)
• Modelling of the various operating cases
• Tools :
• Chemical Engineering commercial Software (Hysys, Pro-II, ….)
• Internal calculation sheets or tools
• Objectives :
• Develop Heat and Mass Balances (HMB’s)
• Develop Process Flow Diagrams (PFD’s)
• Sizing of equipment
• Calculation of utilities consumptions

• Licensors consultations and selection (if any …)

• Preliminary risk analysis
 22 / xx

Simulation & mass balance : Example

Global properties
(P, T, Q…)

Properties of
vapor phase

Properties of
liquid phase

Composition
Process Flow Diagram (PFD) / xx
 Typical engineering project phases / xx

CAPEX ±30%
EPC Contract

CAPEX ±10%
CAPEX/OPEX evaluation FID / EPC ITB

Licensor selection Equipment sizing

Process flow diagrams Process Datasheets
Heat and Mass balances PID’s development
Optimisation

Conceptual Pre-FEED / Procurement

“FEED” Detail Design
or Faisibility “Basic” Construction

3 MONTHS 6 MONTHS 6-12 MONTHS 12-18 MONTHS

24
 / xx

Front End Engineering Design (FEED) &

Engineering Procurement Construction (EPC)

• Development and higher definition of the Basic & pre-FEED

• Specification of equipment and instruments
• Lines sizing
• Safety Studies (Hazid, Hazop, SIL, ….)
• Finalization of utilities consumption & design
• Definition and sizing of Flare networks
• …..

• P&ID’s development (Piping & Instrumentation Diagrams)

• Vendors consultation and incorporation of vendors data in the design

• Incorporation of safety in the design, personnel and environmental protection