CHE 425

CHAPTER 1

Chemical Process Diagrams

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 Chemical Process Diagrams
• Chemical process industry (CPI) and chemical
engineers
• Nature of chemical processes:
– Highly reactive, toxic, corrosive
– Severe operating conditions (high T and P)
• Errors and miscommunications can cause:
– Explosions, environmental damage, health issues.

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Chemical Process Diagrams

THE MOST EFFECTIVE WAY OF

COMMUNICATING INFORMATION
ABOUT A PROCESS IS THROUGH
THE USE OF FLOW DIAGRAMS

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Example

Copyright - R. Turton and J. Shaeiwitz,

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2012
 Stages of a Project
• Engineering  Construction  Commissioning  Start-up 
Normal Operation
• During this operating period, many unforeseen changes are
likely to take place. The quality of the raw materials used by
the plant may change, product specifications may be raised,
production rates may need to be increased, the equipment
performance will decrease because of wear, the development
of new and better catalysts will occur, the costs of utilities will
change, new environmental regulations may be introduced, or
improved equipment may appear on the market.
• As a results, plant operations must be modified and flow
diagrams are updated accordingly.
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 Chemical Process Diagrams
Design is an evolutionary process:

Input/output diagram Generic diagram BFD PFD P&ID

• Input/output is a crude block flow diagram in which only feed and product
streams are identified.

• Generic Diagram Break the process into its basic elements such as reaction and
separation , and recycle sections.

• BFD include the material balance calculations.

• PFD complete mass and energy balance and preliminary equipment specs.

• P&ID includes the mechanical and instrumentation details.

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 Comparison

Level of BFD Level of

Complexity Conceptual
Increases Understanding
Increases
PFD

P&ID

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 The Block Flow Diagram (BFD)
• BFD shows overall processing picture of a
chemical complex
– Flow of raw materials and products may be
included on a BFD
– BFD is a superficial view of facility – ChE
information is missing
• Useful as an orientation tool
• Used to sketch out and screen potential
process alternatives.
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 Definitions of BFD
• Block Flow Process Diagram
– Starting point for developing PFD
– Helpful in conceptualizing new processes
– Similar to sketches in material and energy balances
(CHE201/202)
– Figure 1.1
• Block Flow Plant Diagram
– Gives a general view of a large complex plant
– Limited information is provided
– Figure 1.2

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The Block Flow Process Diagram

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The Block Flow Plant Diagram

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Conventions and Format for BFD
• Operations shown by blocks

• Major flow lines shown with arrows

• Flow goes from left to right whenever possible

• Light streams toward top with heavy stream toward bottom

• Critical information unique to process supplied

• If lines cross, then horizontal line is continuous

• Simplified material balance provided

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 The Process Flow Diagram

• PFD shows all process engineering information

• A PFD contains the bulk of the Chem Engg data

necessary for the design of a chemical process.

• Often PFD is drawn on large paper – certain

information in accompanying tables

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 The Process Flow Diagram
• A typical commercial PFD will contain the following
information:
– All major pieces of equipment in the process will be
represented along with a descriptive name and number.
– All process flow streams will be shown and identified with
a number. A description of the process conditions and
chemical composition of each stream will be included.
– All utility streams supplied to major equipment that
provides a process function will be shown.
– Basic control loops will be shown.

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 The Process Flow Diagram

• Basic information provided by a PFD:

– Process Topology

– Stream Information

– Equipment Information

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 The Process Flow Diagram (cont’d)

– Process Topology
• The location of and interaction between equipment and process
streams is referred as the process topology.
– The topology of the process – showing the connectivity
of all the streams and the equipment
• Example for toluene HDA – Figures 1.3 and 1.5
• Tables 1.2 and 1.4 – list information that should be on the PFD
but cannot fit
• Use appropriate conventions – consistency is important in
communication of process information
ex. Table 1.2

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The Process Flow Diagram (cont’d)

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Common Symbols for Drawing PFD

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 The Process Flow Diagram (cont’d)
Table 1.2 : Conventions Used for Identifying Process Equipment
Process Equipment General Format XX-YZZ A/B
XX are the identification letters for the equipment classification
C - Compressor or Turbine
E - Heat Exchanger
H - Fired Heater
P - Pump
R - Reactor
T - Tower
TK - Storage Tank
V - Vessel
Y designates an area within the plant
ZZ are the number designation for each item in an equipment class
A/B identifies parallel units or backup units not shown on a PFD
Supplemental Information Additional description of equipment given on top of PFD

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 Equipment Numbering
• XX-YZZ A/B/…
– XX represents a 1- or 2-letter designation for the
equipment (P = pump)
– Y is the 1 or 2 digit unit number (1-99)
– ZZ designates the equipment number for the unit
(1-99)
– A/B/… represents the presence of spare
equipment

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 Equipment Numbering

Consider the unit operation P-101A/B

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 Equipment Numbering (cont’d)
Thus, T-905 is the 5th tower in unit nine hundred,
P-301 A/B is the 1st Pump in unit three hundred plus
a spare
• Use unambiguous letters for new equipment
– Ex. Turbine use Tb or J not T (for tower)
– Replace old vessel V-302 with a new one of different
design - use V-319 (say) not V-302 – since it may be
confused with original V-302

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 Example 1.1
Operators report frequent problems with E-102, which are to be investigated. The PFD
for the plant’s 100 area is reviewed, and E-102 is identified as the “Reactor Effluent
Cooler.” The process stream entering the cooler is a mixture of condensable and
noncondensable gases at 654 ˚C that are partially condensed to form a two-phase
mixture. The coolant is water at 30 ˚C. These conditions characterize a complex heat
transfer problem. In addition, operators have noticed that the pressure drop across E-
102 fluctuates wildly at certain times, making control of the process difficult.
Because of the frequent problems with this exchanger, it is recommended that E-102
be replaced by two separate heat exchangers. The first exchanger cools the effluent
gas and generates steam needed in the plant. The second exchanger uses cooling
water to reach the desired exit temperature of 38°C. These exchangers are to be
designated as E-107 (reactor effluent boiler) and E-108 (reactor effluent condenser).

Why E-102 cannot be reassigned to the new equipment?

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 Stream Numbering and Drawing
• Process streams are identified by a number in
a diamond box
• Number streams from left to right as much as
possible
• Horizontal lines are dominant

yes no no
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 Stream Numbering and Drawing (cont’d)

• Add arrows for

– Change in direction
– Inlet of equipment
• Utility streams should use convention given in
Table 1.3, lps, cw, fg, etc.

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 Stream Information

• Since diagrams are small, not much

stream information can be included
• Include important data – around reactors
and towers, etc.
– Flags are used – see toluene HDA diagram
– Full stream data, as indicated in Table 1.4, are
included in a separate flow summary table –
see Table 1.5

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 Flags on PFD

Flags information on PFD

include:
• Temperatures and
pressures associated with
the reactor
• Flowrates of feed and
product streams
• Stream pressures and
temperatures that are
substantially higher than
the rest of the process.

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Stream Information - Flags

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 The Process Flow Diagram (cont’d)
Table 1.4: Information in a Flow Summary
Essential Information
Stream Number
Temperature (°C)
Pressure (bar)
Vapor Fraction
Total Mass Flow Rate (kg/h)
Total Mole Flow Rate (kmol/h)
Individual Component Flow Rates (kmol/h)
Optional Information
Component Mole Fractions
Component Mass Fractions
Individual Component Flow Rates (kg/h)
Volumetric Flow Rates (m3/h)
Significant Physical Properties
Density
Viscosity
Other
Thermodynamic Data
Heat Capacity
Stream Enthalpy
K-values
Stream Name

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 The Process Flow Diagram (cont’d)
A Portion of Table 1.5
Stream Number 1 2 3 4 5 6 7 8 9 10

Temperature (°C) 25 59 25 225 41 600 41 38 654 90

Pressure (bar) 1.90 25.8 25.5 25.2 25.5 25.0 25.5 23.9 24.0 2.6

Vapor Fraction 0.0 0.0 1.00 1.0 1.0 1.0 1.0 1.0 1.0 0.0

Mass Flow (tonne/h) 10.0 13.3 0.82 20.5 6.41 20.5 0.36 9.2 20.9 11.6

Mole Flow (kmol/h) 108.7 144.2 301.0 1204.4 758.8 1204.4 42.6 1100.8 1247.0 142.2

Component Mole Flow

(kmol/h)

Hydrogen 0.0 0.0 286.0 735.4 449.4 735.4 25.2 651.9 652.6 0.02

Methane 0.0 0.0 15.0 317.3 302.2 317.3 16.95 438.3 442.3 0.88

Benzene 0.0 1.0 0.0 7.6 6.6 7.6 0.37 9.55 116.0 106.3

Toluene 108.7 143.2 0.0 144.0 0.7 144.0 0.04 1.05 36.0 35.0

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 Equipment Information
• Equipment are identified by number and a
label (name) positioned above the equipment
on the PFD
• Basic data such as size and key data are
included in a separate table (Equipment
Summary Table) Table 1.7 (and Table 1.6) in
TBWS

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 Equipment Information

A Section of Table 1.7: Equipment Summary

Vessel V-101 V-102

Temperature (ºC) 55 38
Pressure (bar) 2.0 24
Orientation Horizontal Vertical
MOC CS CS
Size
Height/Length (m) 5.9 3.5
Diameter (m) 1.9 1.1
Internals s.p. (splash plate)

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 Basic Control Loops
• Often the basic control loops (those involving
maintaining material balance and reactor
controls) are included on the PFD;
instrumentation and other control loops are
not shown

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Basic Control Loops

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 PFD Summary
• PFD is the first comprehensive diagram drawn for any
new plant or process.
• PFD, Equipment Summary Table, and Flow Summary
Table represent a “true” PFD
• This information is sufficient for a preliminary
estimation of capital investment (Chapter 7) and cost
of manufacture (Chapter 8)
• PFD should remain uncluttered and easy to follow in
order to avoid errors and misunderstandings.

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 The Piping and Instrument Diagram(P&ID)
P&ID – Construction Guide/Manual
• P&ID is also known as mechanical flow diagram
(MFD)
• Contains: plant construction information (piping,
process, instrumentation, and other diagrams)
• Provides information needed by engineers to begin
planning for the construction of the plant

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 P&ID
• P&ID includes every mechanical aspect except

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P&ID

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 Look at V-104 on P&ID
V-104 contains an LE (Level Element)
• LE senses liquid level in separator and adjusts
flow rate leaving
• LE opens and closes a valve depending on
liquid level
• LE and valve represent a feedback control loop

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 P&ID Summary
• The final control element in nearly all chemical process
control loops is a valve.
• Key to understanding the control logic is to identify which
flowrate is being manipulated to control which variable.
• Based on the P&ID diagram:
– Mech and Civil Engrs will design and install pieces of equipment.
– Instrument Engrs will specify, install and check control systems.
– Piping Engrs will develop plant layout and elevation drawings.
– Project Engrs will develop plant and construction schedules.
• Before final acceptance, P&IDs serve as a checklist against
which each item in the plant is checked.
• Design Case Vs Base Case
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 Additional Diagrams
• UTILITY FLOWSHEET
• VESSEL SKETCHES
• WIRING DIAGRAMS
• SITE PLANS
• PLOT PLANS
• ELEVATION DIAGRAMS

DO NOT POSSESS ADDITIONAL PROCESS INFORMATION

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 Other Common Diagrams
• Plot Plans – plan or map drawn looking down
on plant (drawn to scale with all major
equipment identified)
• Elevation Diagrams – show view from side and
give information about equipments distance
from ground

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Other Common Diagrams

Section of Plot Plan Section of Elevation Diagram

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 Other Common Diagrams (cont’d)

• Piping Isometrics – show piping in 3-

dimensions
• Vessel Sketches – show key dimensions of
equipment and locations of inlet and outlet
nozzles etc.

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 Scale Models and Virtual Plants
• 25 years ago physical models were used for review
• Now virtual or electronic models are generated using
software (3-d plant diagrams)
• Purpose of Models – catch errors such as
– Piping clashes
– Misaligned piping
– Equipment not easily accessed
– Sample points not easily reached by operators

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3-D Plant Diagrams

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OPERATOR AND 3-D IMMERSIVE TRAINING SIMULATORS

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OPERATOR AND 3-D IMMERSIVE TRAINING SIMULATORS

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OPERATOR AND 3-D IMMERSIVE TRAINING SIMULATORS

Figure 1.19 An Avatar Can Access Process

trends and Observe Equipment Schematics
in AR (Reproduced by Permission of
Invensys Systems Inc., Property and
Copyright of Invensys plc, UK)

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