Department of Chemical Engineering

VISHWAKARMA INSTITUTE OF TECHNOLOGY, PUNE

666, Upper Indira Nagar, Bibwewadi, Pune 411037

A Presentation on

CHEMICAL PROCESS TECHNOLOGY

Presented by ,

Prof. Amruta Mokashi

Lecture 4: 9thSeptember 2021

 Unit processes

• The unit process is a process in which chemical changes take place to the material present in
the reaction and result in the chemical reaction is known as the Unit process.

• This basically consists of a reaction between two or more chemical which results in another
chemical can also be defined as unit process.

• Example: Sulfonation, nitration, oxidation, halogenation, and many more.

 Types of Chemical engineering drawings

The process diagrams are very useful as they convey the right amount of process information as
needed during various stages of bidding, engineering design, procurement, construction, operating &
decommissioning phases of the process.

Types of process diagrams in chemical engineering context:

1. BFD - Block Flow Diagrams.
2. PFD - Process Flow Diagrams.
3. P&ID - Piping and Instrumentation Diagrams.

In a brief BFD represents entire process in a single sheet, where as in PFD you can find some
detailed information like plant operating conditions, process flow. It uses symbols to represent the
equipment. P&IDs provide detail information when compared to above two drawings. They use
standard nomenclature, symbols, and tag numbers to fully describe the process.
 BFD-Block Flow Diagram

• A BFD has the ability to represent the

complete process on a little more than a
single sheet.
• It contains mainly text enclosed by
boxes, interconnecting lines with flow
arrows.
• In some BFDs mass flow rates may be
mentioned so as to describe the material
balance over the entire plant.
 PFD-Process Flow Diagram

• PFDs contain more information than the

block flow diagrams from which they are
derived.
• They show more detail about major
equipment, subsystems and the flow of
product between them.
• A typical PFD contains equipment
symbols connected by process lines where
temperature and pressure information are
shown on the line itself.
• You can easily refer the properties of a
particular stream through stream number.
• For designing a P&ID, equipment layout
PFD is mandatory.
 P&ID-Piping and Instrumentation Diagram

•P&IDs carry a lot of information to define the

process. Derived from PFD it is the best way of
accurately documenting the operation of a
process. P&ID takes the conceptual aspects of
PFD and expand them by adding

1. Detailed symbols.
2. Detailed equipment information.
3. Equipment order and process sequence.
4. Process and utility piping.
5. Process flow direction.
6. Major and minor bypass lines.
7. Line numbers, Pipe spec, Pipe size.
8. Isolation and shut off valves.
9. Instrumentation controls.
10. Types of process component connections.
 What is a Process Flow Diagram

•This diagram dates back to the 1920s, and in 1921 Frank Gilbreth initiated the “flow process chart.”
Since then, many industrial engineers, businesses, and manufacturers use this chart.
•It is a type of flow chart that is utilized in chemical engineering and process engineering. A process
flow diagram illustrates the equipment and the flow of chemicals included in the process. The PFD only
shows major equipment such as pumps, vessels, columns, heaters, turbines, etc. at an industrial plant.
•However, it does not show minor details or components like designations, flow instruments, pipe
properties, and piping details (drain lines, control loops, bypass lines).
•It’s used to document a process, improve a process or model a new one.
•Depending on its use and content, it may also be called a Process Flow Chart, Flowsheet, Block Flow
Diagram, Schematic Flow Diagram, Macro Flowchart, Top-down Flowchart, Piping and Instrument
Diagram, System Flow Diagram or System Diagram.
 Purpose and benefits

A Process Flow Diagram has multiple purposes:

 To document a process for better understanding, quality control and training of employees.
 To standardize a process for optimal efficiency and repeatability.
 To study a process for efficiency and improvement. It helps to show unnecessary steps,
bottlenecks and other inefficiencies.
 To model a better process or create a brand-new process.
 To communicate and collaborate with diagrams that speak to various roles in the organization or
outside of it.
 Process flow diagram symbols and elements

A typical PFD for a single unit process will include these elements:
 Major equipment: Including names and ID numbers. Examples include compressors, mixers,
vessels, pumps, boilers and coolers.
 Process piping: Moves the product, usually fluids, between equipment pieces.
 Process flow direction
 Control valves and process-critical valves
 Major bypass and recirculation systems
 Operational data: Such as pressure, temperature, density, mass flow rate and mass-energy
balance. Values often will include minimum, normal and maximum.
 Composition of fluids
 Process stream names
 Connections with other systems
 How to research and plan the process flow

• Define the scope of your process to be studied and what you hope to gain.
• Decide on what level of detail is needed for your purposes. For a sophisticated process, different
versions of the diagram may be drawn to communicate with people in different roles.
• For an advanced process such as at an industrial plant, the research may be done through a
project team, quality control group or a consultant. For a smaller, more basic process, you might
do this yourself, perhaps even starting with sticky notes.
• Study the equipment, activities and relationships through observation and interviews. If you’re
modeling a brand-new process, study whatever data is available, including standards for whatever
is being produced in the process.
• Draw a draft diagram and confirm it with people involved in the process. Make any necessary
changes, additions or deletions in collaboration with them.
• Now the diagram(s) can be used for its intended purpose of documentation, quality assurance,
improvement or whatever other goal there might be.
 Tips for process flow diagrams

• These diagrams can have a lot of value for even a basic process. If you’re new to PFDs, try it out,
gathering sufficient detail for your purpose. Don’t worry about the chart itself at first. Just capture
the information on sticky notes or sheets of paper.
• Move on to diagram software once you have your information. With intuitive software
like AspenPlus, it’s not hard to create professional-looking diagrams to clearly communicate a
process flow to your colleagues. The software also may help you to highlight missing data in
your diagram.
• Be consistent with your symbols to avoid confusion. Remember who your intended audience is,
and do whatever makes the most sense to give them what they need for the intended purpose. If
you’re using diagram software, it will include a set of symbols to use.
• On a sophisticated PFD, you may need to use standard symbols such as ISO 10628 to clearly
communicate and collaborate with diverse audiences such as other companies or agencies.
• Include a symbol key on your diagram for clarity.
 Symbol Library for Process Flow Diagram

List of elements that a typical process flow diagram includes for process and chemical engineering.
 Main equipment - Includes ID numbers and names.
Examples: compressors, agitators, centrifuges, apparatus elements, drivers, feeders, engines, mixers,
pumps, separators, valves, coolers, mixers, and boilers.
 Process-critical valves
 Control valves
 Recirculation system
 Major bypass system
 Process of piping
 Flow direction process
 Fluids composition
 Process steam names
 Operational data - It includes temperature, pressure, density, mass-energy balance, and mass flow rate.
 Connections with various systems
 How to Plan and Create a Process Flow Diagram

To plan and create a PFD, you have to follow these steps mentioned below.
● First, you need to define your process’s scope. Mention what you want to study and what you will
obtain from it.
• Next, decide what kind of details you will need for your purpose. Various editions of PFDs are
available for intricate processes that you can use or draw to communicate with people.
● It is essential to study relationships, activities, and equipment with the help of interviews and
observations. If you are making a new process model, try to learn and understand the available data.
Furthermore, it is crucial to study the standards of whatever you are trying to produce in the process.
● Now draw a rough sketch and confirm it with your team members. It is vital to make a draft and
seek approval from the people involved in this process because it will help you to make necessary
changes, you can add stuff, or delete any errors.
● Finally, your diagram is ready to be used for its intended purpose. Your goal might be to provide
quality assurance, documentation, or improvement.
 Process steps

As an elementary approach to most chemical processes, the following broad steps can usually be
considered,
• Prepare the reactor
• React them
• Separate the product
• Purify the product
 Design Steps

• Collect all laboratory and process development information.

• Prepare flow sheets.
• Choose conventional design procedures for equipment designated on flow sheets as unit
operations oriented.
• Design the reactors, this is one of the major problems of the plant design job; optimum design is
critical.
• Select control instrumentation for process monitoring and analysis.
• Select and size materials handling equipment- pumps, piping, conveyors, etc.
• Design all auxiliaries
• Make plant layout
• Itemize all designs for cost estimating