2024-04-20

Process Design
Muhammad Abdus Salam, PhD
Associate Professor
Department of Chemical Engnineering and Polymer Science
Shahjalal University of Science and Technology
Sylhet

Course contents
• Introduction to Process Design: The Nature of Chemical Process Design and
Integration Organizational Structure, Plant design and process design, Role of
the Process Design Engineer, Scope of Design, Design basis, Feasibility survey
and site selection for plant design, standard and code, materials and energy
balance of process.

• Flow-Sheeting: Flow-sheets-Types, Flow- sheet Presentation, Flow-sheet

Symbols, Plant Layout.

• Piping and instrumentation: P & I diagram, valve selection, pumping of liquids,

pump selection, and pipe size selection.

• Control and Instrumentation: instrumentation and control objectives, typical

control systems.

• Heat Exchanger Networks: Heat Transfer Equipment, Energy Targets and

Network Design: Pinch Technology.

• Equipments Selection and Specification and Design: Heat exchanger,

evaporator, Distillation Column, agitator, Ion-exchange column, compressor,
pump, cooling tower.
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• Materials of Construction: Material properties, Mechanical proper ties,
Selection for corrosion resistance.

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Course Outlines…..
• Combination of lectures and exercises/simulation
• Assignment are compulsory ( 2 to 3 assigmnets)
• Random class performance (10)
• Class attendance (10).
• Term test (TT-1 after 9 th lecture, TT-2 after 15 th lecture)

Course……integrates your previous knowledge in chemical engineering

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We start with a conceptual process!

𝑭𝒆𝒆𝒅 ↔ 𝑷𝒓𝒐𝒅𝒖𝒄𝒕 + 𝑼𝒏𝒓𝒆𝒂𝒄𝒕𝒆𝒅 𝒇𝒆𝒆𝒅 𝑭𝒆𝒆𝒅 ↔ 𝑷𝒓𝒐𝒅𝒖𝒄𝒕 + 𝑩𝒚𝒑𝒓𝒐𝒅𝒖𝒄𝒕
𝑷𝒓𝒐𝒅𝒖𝒄𝒕 ↔ 𝑩𝒚𝒑𝒓𝒐𝒅𝒖𝒄𝒕 𝑭𝒆𝒆𝒅 ↔ 𝑩𝒚𝒑𝒓𝒐𝒅𝒖𝒄𝒕

Do you see any information?

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More…..

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More…..
Thus, rather than relying
on recycled product
to limit the temperature
rise (fall), simply opt for
a low conversion, a high
recycle of feed and a
resulting small
temperature change in the
reactor

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More…..

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So……….When recycle necessary?

• Low reactor conversion
• Byproduct formation
• Impure feed
• Reactor inerts/diluents/solvents
• Heat carrier

Recycle good or bad?

Configuration of recycle?

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Nature of Chemical
Bulk Chemicals
Fine Chemicals
Specialty/effect/functional
chemicals
Life cycles

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Example 13.1

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Example 13.1

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Introduction to Process Design

• Niche/Design problem/need
Niche/Design
• New materials/process/technology problem/need

• Preliminary design (derive a process

flowsheet and evaluate it or them!)/basic Construction,
Preliminary
process design/detailed engineering comissioning
and startup
design (PFD)

design, startup and operation.

• Materials/Energy balance, Processing
conditions (flow, temperature, pressure)
determination.
Detailed
• Economic/risk/safety evaluation engineering
Economic/de
sign
design Evaluation

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Introduction to Process Design

• Design need/objective/Constraints
complete, and clear-cut statement of the
requirements.
must haves,

should haves

Design constraints

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Introduction to Process Design

• Design basis
The design basis is a more precise statement of the problem
that is to be solved

• The system of units to be used.

• The national, local or company design codes that
must be followed.
• Details of raw materials that are available.
• Information on potential sites where the plant might
be located, including climate data, seismic
conditions, and infrastructure availability.
• Information on the conditions, availability, and price
of utility services such as fuel (gas), steam, cooling
water, process air, process water, and electricity, that
will be needed to run the process.

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Process Diagram:
 In general, chemical processes are complex, and chemical engineers in
industry encounter a variety of chemical process flow diagrams.

 It is essential that chemical engineers be able to formulate appropriate

process diagrams and be skilled in analyzing and interpreting
diagrams prepared by others.

 The most effective way of communicating information about a process

is through the use of flow diagrams.

 Typical Process Diagrams are:

 Block Flow Diagram (BFD)
 Process Flow Diagram (PFD)
 Piping/Process and Instrumentation Diagram (P & ID)

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Block Flow Diagram:

 This diagram consists of a series of blocks representing different equipment or unit
operations that are connected by input and output streams.

 Each block in the diagram represents a process function and may, in reality,
consist of several pieces of equipment
 Important information such as operating temperatures, pressures, conversions,
and yield are included on the diagram along with flow rates and some chemical
compositions.
 The diagram does not include any details of equipment within any of the blocks.

 The block flow diagram can take one of two forms. First, a block flow process
diagram and the second a block flow plant diagram.

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Block Flow Diagram:

 Although much information is missing such a diagram is very useful
for “getting a feel” for the process.

 Block flow process diagrams often form the starting point for
developing a PFD.

 They are also very helpful in conceptualizing new processes and

explaining the main features of the process without getting bogged
down in the details.
 Example:
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.
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Block Flow Process Diagram:

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Convention & 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.

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Advantage of BFD:
 Complete picture of what plant does and how all the different
processes interacts.

 Diagram is relatively uncluttered

 BFD’s are used to sketch out and screen potential process alternatives.
Thus, they are used to convey information necessary to make early
comparisons and eliminate competing alternatives without having to
make detailed and costly comparisons.

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Process Flow Diagram (PFD):

 The process flow diagram (PFD) represents a quantum step up from the BFD in terms of
the amount of information that it contains.
 A simplified sketch that uses symbols to identify instruments and vessels and to describe
the primary flow path through a unit.
 A process flow diagram provides a quick snapshot of the operating unit.

 Flow diagrams include all primary equipment and flows. A technician can use this
document to trace the primary flow of chemicals through the unit. Secondary or minor
flows are not included. Complex control loops and instrumentation are not included.

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Process Flow Diagram (PFD):

 A typical commercial PFD will contain the following information:
i. All the major pieces of equipment in the process will be represented
on the diagram along with a description of the equipment. Each piece
of equipment will have assigned a unique equipment number and a
descriptive name.
ii. All process flow streams will be shown and identified by a number. A
description of the process conditions and chemical composition of
each stream will be included. These data will be either displayed
directly on the PFD or included in an accompanying flow summary
table.
iii. All utility streams supplied to major equipment that provides a
process function will be shown.
iv. Basic control loops, illustrating the control strategy used to operate
the process during normal operations, will be shown.

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Typical Process Flow Diagram (PFD):

The basic information

provided by a PFD can
be categorized into one
of the following:

1. Process topology
2. Stream information
3. Equipment
information

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Symbols for Drawing PFD:

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Conventions for drawing PFD:

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Conventions for drawing PFD:

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Conventions for drawing PFD:

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P&I Diagram :
 A process and instrument drawing is more complex. The P&ID includes a graphic
representation of the equipment, piping, and instrumentation. Modern process control can
be clearly inserted into the drawing to provide a process technician with a complete picture
of electronic and instrument systems. Pressure, temperature, flow, and level control loops
are all included on the unit P&ID.

 Provides information needed by engineers to begin planning for the construction of the
plant
 The P&ID includes every mechanical aspect of the plant except the information given in
Table:

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Piping and Instrument Symbol:

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Process Legend:
 The process legend provides the
information needed to interpret and
read the P&ID.

 Process legends are found at the

front of the P&ID.

 The legend includes information

about piping, instrument and
equipment symbols, abbreviations,
unit name, drawing number,
revision number, approvals, and
company prefixes.

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Steps in design synthesis

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