Chemical Process Technology

(CHC503)

Dr. Rajib Ghosh Chaudhuri

Department of Chemical Engineering
NIT Durgapur.
Contact Detail: rajib.ghoshchaudhuri@che.nitdgp.ac.in
+91 7596854649
Referred Books
Text Book [TB]:
1. M Gopala Rao and Marshall Sittig "Dryden’s Outlines of
Chemical Technology for the 21st Century" Edited by. East
West Press, 3rd Ed., 1997. Reprint 2007.

Reference books [RB]:

1. George T. Austin, Shreve’s Chemical Process Industries,
McGraw Hill, 5th Ed., 1984.
2. Jacob A Moulijn, Chemical Process Technology, John Wiley,
2007.
3. Charles E, Thomas, Introduction to Process Technology, 3rd
Ed. 2010.
4. Andre de Haan, Process Technology, 2015.

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Syllabus
Module I: Introduction; Water Treatment; Industrial production of
O2 and N2; Cement, glass, ceramic industries
Module II: Chlor-alkali industries (Soda-ash, NaOH, Cl2)
Module III: Industrial Acids (H2SO4, HCl, HNO3, H3PO4)
Module IV: Fertilizer Industry (NH3, Urea, NPK Fertilizers)
Module V: Organic Chemical industries (Oils & Fats; Soaps,
Detergents & Glycerin; Sugar and starch industries; Pulp and paper
Industries)

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 Chemical Process Diagram (PID Diagram)
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Chemical Industries – Facts and figures

Share
(%)
China 40.6
European Union 14.8
NAFTA* 15.5
Rest of Asia 9.9
Japan 4.6
Korea, Republic 3.2
Other Europe 4.6
Latin America 3.5
* North American Free Trade Agreement India 2.5
Canada, Mexico, and the United States Africa 0.7
Rest of the World 0.1
World 100
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Production volume of major chemicals in India from
financial year 2013 to 2021

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Role of Chemical Engineers in Chemical Process Industries
Chemical engineering is that branch of engineering concerned with the
development and application of manufacturing processes in which
chemical or certain physical changes of materials are involved.
Chemists Chemical Engineers
 Design reaction pathways to  Design a process to scale the
produce a chemical from raw chemist’s process to mass
materials produce the product
 Work in the laboratory setting to
 Work in a chemical plant to
produce material on the gram
produce material in the ton and
to kilogram scale
beyond range

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Working in the Chemical Processing Industry
 Preparation and Basic Skills
Preparation for work in the chemical processing industry starts early for a
process technician.
 Reading Writing
 Listening Computer Technology
 Interpersonal Skills and Communication
 Scientific Principles
Fundamentals of chemistry—atoms, elements, atomic structure,
hydrocarbons, states of matter, gases, solutions
• Physics—fluids, temperature, pressure, heat transfer, work, and energy
• Math and statistics
• Basic equipment and technology
• On-the-job skills
 Punctuality
 Problem Solving
 Safety, Quality and Environmental Awareness

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Past and Present Concept of Industrial Development

Past Concept Present Concept

Social Economic Development

Environment

Nobody was bothering during the fifties about In present scenario

the environment, it was the more the the development is just to consider all
economic development just to meet the integrated approach, that is the economic
demands of the people, to meet the food and development, environment safety and
grain that was the important part in case of health. Even in case of the environment
the earlier development. earlier it was the only environment then it
came the environment health and safety
and that was the HSE.
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Unit Operation and Unit Process
 Commercial Production = f (Physical change + Chemical
change)
 In any chemical production basically three steps
 Pre process [Unit Operation]
 Process [Unit Process]
 Post process [Unit Operation]

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Pre and Post-Treatment Operation
Pre and Post-Treatment Operation consist of:
• Fluid flow (including fluids transportation, filtration, and solids
fluidization)
• Heat transfer (including evaporation and heat exchange)
• Mass transfer (including gas absorption, distillation, extraction,
adsorption, and drying)
• Mechanical Operation
• Control and Instrumentation

Mechanical separation

– gravity
– centrifugal
– impingement
– electrostatic
– magnetic

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Unit Operation

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Unit Operation

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Unit Operation

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Unit Processes

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Unit Processes

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Chemical Plant Layout

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Chemical Plant Layout

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 1. Block Flow 2. Process Flow
Diagram (BFD) Diagram (PFD)

PROCESS
DIAGRAMS

4. Piping and 3. Process equipments

Instrumentation symbol and
Diagram (P&ID) numbering
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Block Flow Diagram (BFD)
 Is the simplest flowsheet
 Process engineer begins the process design with a block diagram
in which only the feed and product streams are identified
 Input-output diagrams are not very detailed and are most useful
in early stages of process development
 Flow of raw materials and products may be included on a BFD
 The processes described in the BFD, are then broken down into
basic functional elements such as reaction and separation
sections
 Also identify the recycle streams and additional unit operations
to achieve the desired operating conditions

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Block Flow Diagram (BFD)
Block Flow Diagram for the Production of Benzene
Reaction : C7H8 + H2 C6H6 + CH4

Mixed Gas
Toluene, C7H8 2610 kg/hr
10,000 kg/hr

Reactor Gas Separator Benzene, C6H6

C6H6
8,210 kg/hr
CH4
Hydrogen H2
820 kg/hr C7H8
Mixed Liquid

75% Conversion of
Toluene

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 Sulfuric Acid
S (S )  O2 ( g )  SO2 (g) ΔH  70Kcal

1
SO2 ( g )  O2 ( g )    SO3 (g)
V2 O 5 catalyst
ΔH  23Kcal/mole
2
SO3(g)  H 2 SO4(l)  H 2 S 2O7(l)
H 2 S 2O7(l)  H 2O(l )  2 H 2 SO4 (l )

Raw
material Sulfur Sulfur SO2 SO3 H2SO4
Purification Burner Converter Absorption

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Production of Ethane from Ethanol
Ethanol is feed to continuous reactor with presence of sulphuric acid catalyzer to
produce ethylene. Distillation process then will be applied to separate ethylene-
H2O mixture. Ethylene as a top product is then condensate with condenser to
perform liquid ethylene. Hydrogenation of ethylene applies in another reactor
with presence of Nickel catalyst to produce ethane as a final product. Develop
BFD for these processes.
CH3CH2OH H2SO4 CH2=CH2 + H2O

CH2=CH2 + H2 CH3CH3
Ni

Answer: Hot water

out
Ethylene, Ethylene liq.
CH2CH2 (g) CH2CH2 (l)

Ethanol,

C2H5OH Cold Ethane,

Reactor 1
CH2CH2 Reactor 2
water in CH3CH3
H2SO4 H 2O Hydrogen,
H2 Ni
H2O
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Process Flow Diagram (PFD)
A Process Flow Diagram generally includes following
information;

a) Flow rate of each stream in case of continuous process or

quality of each reactant in case of a batch process.
b) Composition streams.
c) Operating conditions of each stream such as pressure,
temperature, concentration, etc.
d) Heat added or removed in a particular equipment.
e) Flows of utilities such as stream, cooling water, brine, hot oil,
chilled water, thermal fluid, etc.
f) Major equipment symbols, names and identification.
g) Any specific information which is useful in understanding the
process. For example, symbolic presentation of a hazard,
safety precautions, sequence of flow, etc.

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Process Flow Diagram (PFD)
 Major Pieces of Equipment
 Utility Streams
 Process Flow Streams
 Basic Control Loops

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Process Flow Diagram (PFD)

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Major pieces of equipment and utility streams
Process Unit Symbols
Symbol Description Symbol Description

Heater coil
Heat exchanger

H2O Water cooler Centrifugal pump

S Steam heater Turbine type compressor

Cooling coil Pressure gauge

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Major pieces of equipment and utility streams
Process Unit Symbols
Symbol Name Description

Stripper A separator unit used

commonly to liquid mixture
into gas phase.

Absorber A separator unit used

commonly to extract mixture
gas into liquid phase.

A separator unit used

Distillation commonly to crack liquid
column contains miscellaneous
component fractions.

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Major pieces of equipment and utility streams
Process Unit Symbols
Symbol Name Description
A process unit that used to mix
Liquid mixer several components of liquid.
or

Reaction A process unit where chemical

process reaction occurs
chamber

Horizontal tank A unit to store liquid or gas.

or cylinder

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Major pieces of equipment and utility streams
Process Unit Symbols
Symbol Name Description

Boiler A unit for heating.

Centrifuge A separator unit that to

physically separated liquid
mixture. (exp: oil-liquid)

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Process Flow Diagram (PFD)
Valve Symbology
Symbol Name
Name Symbol

Gate Valve Needle Valve

Globe Valve 3-Way Valve

Ball Valve Angle Valve

Check Valve

Butterfly Valve

Relief Valve
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PFD Diagram of Production of Ethane from Ethanol
Ethanol is feed to continuous reactor with presence of Acid Sulphuric catalyzer to produce ethylene. Distillation process
then will be applied to separate ethylene-H2O mixture. Ethylene as a top product is then condensate with condenser to
perform liquid ethylene. Hydrogenation of ethylene applies in another reactor with presence of Nickel catalyzer to
produce ethane as a final product. Develop PFD for these processes. H SO
2 4
CH3CH2OH CH2=CH2 + H2O
Ni CH3CH3
CH2=CH2 + H2

Hot water
Ethylene, out Ethylene liq.
Ethanol, CH2CH2 (g) CH2CH2 (l)
C2H5OH CH2CH2 Cold Hydrogen, H Ethane,
Reactor 1 Reactor 2
water in 2 CH3CH3
H2SO4 H 2O
Ni
H2O
R-100 P-100 T-100 E-100 P-101 R-101
Reactor Pump Distillation Column Condenser Pump Reactor
Hot water out

Ethylene E- Ethylene
100 V-
Cold water 104 liq.
T- in V-
CV-100 CV-101 106
Ethanol 100 V-

H2SO4 V- V-
101V-
V-
102
105
Hydroge
100 V-
R-
100 103 107 n Ni R- Ethane
P- 101
32 100 H2 P-
101
O
Process Flow Diagram (PFD)
Production of C6H6 from Toluene Mixed Gas
Toluene, C7H8 2610 kg/hr
10,000 kg/hr
Reactor Gas Separator Benzene, C6H6
C6H6
8,210 kg/hr
Hydrogen H2 CH4
820 kg/hr Mixed Liquid
C7H8
75% Conversion of
Toluene

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Process Flow Diagram

Hot water
Hot water out
out
Ethylene
Ethylene

Cold Ethylene liq.

Ethanol Ethylene liq.
Cold water in
water in Ethanol
H2SO4
H2SO4 Hydrogen Ethane
Hydrogen Ethane Ni
Ni H2O
H2O
P-100 A

P-100 A/B
P-100 B

In PFD In Real Plant

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 Process instrumentation

 TYPES of piping and instrumentation symbols.

 How to CHOOSE the suitable symbols in Process Flow

Diagram?

 How to DEVELOP the piping systems and the

specification of the process instrumentation, equipment,
piping, valves, fittings.

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Piping and Instrumentation Diagram (P&ID)
The piping and instrumentation diagram (P&ID), also known as
MECHANICAL FLOW DIAGRAM (MFD), provides information
needed by engineers to begin planning for the construction of the
plant.

1. Operating Conditions T, P
2. Stream Flows
3. Equipment Locations
4. Pipe Routing
a. Pipe Lengths
b. Pipe Fittings
5. Supports, Structures, and Foundations

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Piping and Instrumentation Diagram (PID)
Piping and Instrumentation (P&ID) Diagram
The piping and instrumentation diagram (P&ID), also known as
mechanical flow diagram (MFD), provides information needed by
engineers to begin planning for the construction of the plant.
Instrumentation Symbology

Instruments that are field mounted.

-Instruments that are mounted on process
plant (i.e., sensor that mounted on pipeline
or process equipment)

Instruments that are board mounted

-Instruments that are mounted on control board.

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Instrumentation Symbology
Instruments that are board mounted
(invisible).
-Instruments that are mounted behind a control
panel board.

Instruments that are functioned in Distributed

Control System (DCS)
- A distributed control system (DCS) refers to
a control system usually of a manufacturing
system, process or any kind of dynamic
system, in which the controller elements are
not central in location (like the brain) but are
distributed throughout the system with each
component sub-system controlled by one or
more controllers. The entire system of
controllers is connected by networks for
communication and monitoring.
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PROCESS FLOW DIAGRAM (PFD)

Stream Numbering and Drawing

- Number streams from left to right as much as possible.

- Horizontal lines are dominant.

Yes No No
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Identification Letter and TAG Number

• The initial letter indicates the measured variable.

• The second letter indicates a modifier, readout, or device function.
• The third letter usually indicates either a device function or a
modifier.
• Numbers on P&ID symbols represent instrument tag numbers.
• Often these numbers are associated with a particular control loop
(e.g., flow transmitter 123).

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Piping and Instrumentation (P&ID) Diagram
Instrumentation Numbering

 XYY CZZLL

X represents a process variable to be measured.

(T=temperature, F=flow, P=pressure, L=level)

YY represents type of instruments.

C designates the instruments area within the plant.

ZZ designates the process unit number.

LL designates the loop number.

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Piping and Instrumentation (P&ID) Diagram
Signal Lines Symbology

*A heavy solid line represents piping

A thin solid line represents process connections to instruments (e.g., impulse piping)
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Conventions Used for Identifying Instrumentation on
P&IDs (ISA standard ISA-S5-1)

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Piping and Instrumentation (P&ID) Diagram

L = Level shall be measured.

 LIC 10003 IC = Indicating controller.
100 = Process unit no. 100 in the area of no. 1
03 = Loop number 3

LC

With using these following symbols;

LV 100
V-100 LC
LT Distributed Control System

Pneumatic line
Complete control loop for LCV 101
LCV 101

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 PFD
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 P&ID
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Piping and Instrumentation Diagram (P&ID)
Block Diagram

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Specified Engineering Flow Sheet

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