Chemical Process Diagrams

After completing this chapter, students should be able to

 appreciate different types of chemical process diagrams
 understand how these diagrams represent
 know how to draw chemical process flow diagrams
 understand the information included in a chemical process diagram
 apply knowledge regarding chemical process flow diagrams on his/her own term project task
Chemical plants produce a wide variety of products through various types of chemical processes
These chemical processes are complex and usually involve substances that are reactive, toxic, and
corrosive.
Additionally, they are often operated at high temperatures and pressures. These characteristics of
chemical processes can lead to accidental fires and explosions, environmental damage, and threats to
the human’s health. Accordingly, any errors or omissions resulted from miscommunications during the
designs and operations of chemical processes must be avoided. Visual information is the clearest way
and can be conceived as an international language to present the material and is unlikely to be
misinterpreted. For chemical processes, such visual information is presented as chemical process
diagrams.
A chemical process diagram evolves from the time when a process is conceived in a laboratory through
the design, construction, operation, and modification of a chemical process/plant.
From the time that a chemical plant starts to operate, an investor has to wait for several years to
produce sufficient revenue to pay for all plant operations and to repay all costs related to the designing
and building of the chemical plant.
Moreover, during the operation, several changes are likely to take place
Such changes include:
 the qualities or specifications of raw materials
 the needs of customers on product qualities and specifications
 the production rates (to keep up with increasing demands)
 the equipment performance, which decreases over time because of wear
 the costs of utilities or the development of new and better catalysts, which affect how the
plants are operated
 the environmental laws and regulations
To modify or improve the plant, it must be done through the chemical process diagrams; these diagrams
act as a primary basis for understanding any changes taking place in the chemical plant.
The chemical process diagrams that are essential to engineers include
 block flow diagrams (BFD)
 process flow diagrams (PFD)
 piping and instrumentation diagrams (P&ID)
1 Block Flow Diagrams (BFD)
Students should be familiar with block flow diagrams (or flow charts) as they were introduced in the first
engineering course of Material & Energy Balances
A block flow diagram (BFD) is the way that an engineer convert a narrative form of problem into an
easy-to-understand block diagram.
The BFD should consist of
 a series of blocks representing process equipment or unit operations
  the details of input and output streams, including flow rates and compositions
 operating temperatures and pressures, as well as conversion and yield
However, the details of each equipment or unit operation are not to be included in the BFD, to make the
BFD as uncluttered as possible. The BFD gives a clear overview of a chemical process, and it serves as a
starting point to develop a process flow diagram (PFD).
The BFD can be categorized into 2 types:
 Type I: block flow process diagram, which provides an overview of a chemical process
 Type II: block flow plant diagram, which gives an overview of the whole chemical plant
An example of a block flow plant diagram is illustrated in Figure 4.1

In this type of BFD, each block represents a process function or unit operation, which, in reality, may
consist of several pieces of equipment.
The number in circle (at times, it may be presented as a number in a diamond box) indicated in each
stream is called a stream number, which corresponds to the information of that stream appeared in the
flow summary table provided as a separate attachment to the BFD.
It is noteworthy that the trapezoids in the diagram represent compressors and turbines.
This diagram gives a complete picture of a chemical process plant; i.e. what the plant does and how all
different processes interact to each other/one another.
The block flow process diagram provides an overview of a particular process, which may be a part of the
whole chemical plant.
Let’s consider how we can translate the narrative description of a chemical process to a block flow
process diagram.
From the following description [1]:
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 non-condensable gases are separated
and discharged. The benzene- toluene product is separated by distillation. The toluene is then recycled
back to the reactor, and the benzene is obtained in the product stream.

it can be converted to a block flow process diagram as shown in Figure 4.2

Figure 4.2 A block flow process diagram for the production of benzene from the reaction of toluene and
hydrogen (type I). It is evident that only a little information (e.g., equipment name, stream information,
including flow rates) is included in the block flow process diagram.
The following are the recommended conventions and formats of a block flow process diagram.
1. Unit operations are shown by blocks
2. Major flow lines (streams) are shown by lines with arrows to give directions of the flow
3. Lines are horizontal and/or vertical, with turns at 90 degree angles
4. The flow goes from left to right
5. Light streams (e.g., gases) go towards the top, whereas heavy streams (e.g., liquid) are drawn
towards the bottom.
6. Essential information unique to the process(e.g., flow rates, conversion) is supplied
7. If lines cross each other, the horizontal line is continuous, whereas the vertical line is broken or
has a go-over sign
8. A simplified material balance should be provided (Seider et al., 2004)
Example 2: Oxidation of Propene to Acrylic Acid
Propane is dehydrogenated to propene, which is oxidized to acrolein first and then further oxidized to
acrylic acid. The products are separated in the end to give acrylic acid and various by-products. The by-
products are further separated to yield a propane recycle stream. Each block in the BFD provided shows
what each individual unit is doing along every step of the process. It also shows inlet and outlet streams,
as well as By products and recycle streams. A BFD in this style is helpful so that all materials can be seen,
every step of the process is outlined, and byproducts can be taken into consideration for waste
removal/treatment.

2 Process Flow Diagram (PFD)

As mentioned earlier, block flow diagrams (BFD) can be developed to more sophisticated chemical
process flow diagrams (PFD) or process flow sheet (PFS).
The PFD contains a bulk of chemical engineering data necessary for the design of a chemical process.
Note that the PFD of one chemical plant may differ from that of others; however, the typical PFD should
contain the following information [1]:
1. All major equipment in the process; each equipment will have an assigned equipment number
and descriptive name
2. All process flow streams are shown and identified by a number (in circle or diamond box)
3. Each stream must be given with conditions (e.g., temperature and pressure) and compositions
(note that this information can either be included directly to the stream in the PFD or provided
separately as a flow summary table)
4. All utility streams supplied to major equipment are also included in the PFD
5. Basic control loops, illustrating the control technique, are shown in the PFD as well.
The PFD is a very complex diagram, but it must remain uncluttered and easy to understand, to avoid any
errors (e.g., misinformation or misinterpretation), which can lead to the operation catastrophes.
The basic information provided by the PFD can be categorised into
 process topology
 stream information
 equipment information
2.1 Process topology
A process topology is referred to the location and interaction between equipment and process streams
Note that the diagram, as depicted in Figure 4.3, is commonly called a skeleton process flow diagram.
Equipment is represented symbolically by icons or symbols, which identify unit operations.
Figure 4.3 A skeleton process flow diagram (PFD) for the production of benzene via the hydridealkylation
of toluene
Standard icons or symbols representing equipment are illustrated in Figure 4.4A-E

At the top of the skeleton flow diagram (Figure 4.3), the equipment numbers and their corresponding
descriptive names are listed (from left to right).

The initial input streams are represented by circles with half black on the left while the final

output streams are depicted by circles with half back on the right .

An example of how we can use the information in the PFD is as follows: the unit operation
P-101 A/B means.
 It is a pump (P) [to be specific, it is a reciprocating pump]
 it is located in the area 100 of the plant.
 it is the pump # 01
 there are 2 identical pumps: pump P-101A and pump P-101B, and one pump is operating while
another pump is idle
a) PFD symbols for valves
b) PFD symbols for reactors, vessels, mixers, and tanks

c) PFD symbols for heat transfer equipment

d) PFD symbols for fluid-handling equipment

e) PFD symbols for solid-handling equipment

f) PFD symbols used with other symbols

2.2 Stream information
The process streams in the PFD are generally identified by the stream numbers in circles or diamonds, as
shown in Figure 4.3, and the flow directions are indicated by arrows.
The detailed information of each stream is normally given as a separated stream/flow summary table, to
keep the PFD uncluttered.
The utility streams are identified by initials, and the standard initials for utility streams are as follows.
 lps = low-pressure steam (3-5 bar)
 mps = medium-pressure steam (10-15 bar)
 hps = high-pressure steam (40-50 bar)
 cw = cooling water (in = 30 oC and out < 45 oC)
 rw = refrigerated water (in = 5 and out < 15 oC
 fw = fire water
 wr = river water (in = 25 oC and out < 35 oC
 rb = refrigerated brine (in = -45 oC and out < 0 oC
The information of each stream (or flow) presented in the flow summary table includes
Required information
 Stream number
 Temperature
 Pressure
 Vapour/liquid fraction
 Total mass/mole flow rate with component mass/mole fraction
Optional information
 Component mass/mole fraction
 Individual component flow rate
 Volumetric flow rate
 Significant physical properties (e.g., density, viscosity)
 Thermodynamic data (e.g., specific heat capacity, stream enthalpy, K values)

2.3 Equipment information

The summary of the equipment appeared in the PFD provides the information essential to estimate the
costs of equipment and supply the basis for the detailed design of equipment
The information required for each type of equipment is as follows.

Towers
 Height and diameter
 Temperature (T) and pressure (P)
 Number and type of trays/height and type of packing
 Materials of construction (MOC)
Heat exchangers
Type: gas-gas, gas-liquid, liquid liquid, condenser, evaporator
 Duty (heating/cooling rate)
Area
T and P of both streams
Number of shell and tube passes
MOC (both shell and tubes)
Heaters
 Type (e.g., coal-fired, electric)
 Tube pressure
 Duty
 Fuel
 MOC
Tanks and vessels
 Height and diameter
 Orientation (horizontal or vertical)
 T and P
 MOC

Pumps
 Flow rate
 Discharge pressure
 T
 Pressure drop across the pump (DP)
 Driver type (e.g., reciprocating, centrifugal)
 Shaft power (in kW or hp)
 MOC
2.4 Combining topology, stream information, and control strategy to form a PFD
When combining the skeleton process flow diagram (Figure 4.3) with the information on the major
control loops employed in the process, it yields a complete process flow diagram (PFD), as shown in the
Figure below
The PFD is the first comprehensive diagram for a new chemical plant/process
It gives sufficient information required for
 material and energy balances (to establish process control protocol)
 cost estimation (to determine the economic viability of the process)
Additionally, the PFD can also be used
 to diagnose operating problems
 for predicting of the changes in major process variables on the process
 in the training of new engineers and/or plant operators

3.0 Piping and Instrumentation Diagrams (P&ID)

The piping and instrumentation diagram (P&ID), also known as mechanical flow diagram (MFD),
provides information required by engineers planning to construct the chemical plant Each PFD (e.g.,
Figure 4.5) requires several P&IDs for each section of the process
Figure 4.6 is an illustration of the P&ID for the distillation section of the benzene-production process
It provides information on the piping in the process Utility connections are identified by numbers in
boxes. All process information that can be measured in the plant is shown on the P&ID by circular flags
The conventions used to identify instrumentation (i.e. how the measurements are taken and
how the information is dealt with) on the P&ID are summarised in Table 4.3
Identification Letters ( ISA standard)
The following letters are used to describe the control devices involved in a
process. Each device is labeled with two letters. The first letter describes the
parameter the device is intended to control. The second letter describes the type
of control device. For example, the symbol “PI,” is a “pressure indicator.”
Tag Numbers: Tag “numbers” are letters and numbers placed within or near the
instrument to identify the type and function of the device.
Tag Descriptors
Examples of how interpret the symbols are as follows

 LIC in indicates that it is a level (L) indicator (I) and controller (C) located on the front of the
panel in the control room
 TT in means that it is a temperature (T) transmitter (T) located in the plant sending the
information (signal) regarding the temperature to the control room.
 FI in implies that it is a flow rate (F) indicator (I) [cannot be controlled] located in the
plant

 PY in indicates that it is a pressure (P) relay (Y) located in the front of the panel in the
control room receiving the signal from the plant.
 LE in means that it is a level (L) sensing element (E) located in the plant [note that this
element is usually followed by a transmitter (T) to send the signal to the control room]