Module-1

Dr. K. Sivagami,
Associate Professor ,
School of Chemical
Engineering,
VIT Vellore
 Type of Max. marks for which the Marks in previous
Evaluation exam is conducted column are
converted to
Mid Term Exam 50 marks 30 marks
2 Quizzes Each quiz will be 20marks
conducted for a minimum (10marks from each
of 10 marks quiz)
Assignment In the form of a report, 10marks
seminar, presentation,
quiz, experiment

TEE(Theory 60 marks 40 marks

without a lab
component)
Total 100 marks
 Specifying the Problem ( Problem Statement)
 Analyzing the probable solution
 Applying Chemical Process Principles and
theories of mechanics to satisfy the
conditions of problem

 Selecting materials and stresses to suits

process conditions
 Evaluating and optimizing the design
 Preparing the drawings and specifications
1. Optimum processing conditions
2. Appropriate materials of construction
3. Strength and rigidity of components
4. Satisfactory performance of mechanisms
5. Reliable methods of fabrication
6. Ease of maintenance and repairs
7. Ease of operation and Control
8. Safety Requirements
• Raw material storage : if the raw material supply is
inadequate or non- continuous, then the provisions has to
be made to store the raw material, to smooth out
fluctuations and interruptions in supply.

• Feed preparation : Some purification, and preparation,

of the raw materials will usually be necessary before they
are sufficiently pure, or in the right form, to be fed to the
reaction stage
• Reactor : The reaction stage is the heart of a chemical
manufacturing process.

• In the reactor the raw materials are brought together

under conditions that promote the production of the
desired product; invariably, by-products and unwanted
compounds (impurities) will also be formed.

• Product separation : In this first stage after the reactor

the products and by-products are separated from any
unreacted material.
• In sufficient quantity, the unreacted material will be
recycled to the reactor.
• They may be returned directly to the reactor, or to the
feed purification and preparation stage.
• The by-products may also be separated from the
products at this stage.
• Purification: Before sale, the main product will usually
need purification to meet the product specification. If
produced in economic quantities, the by- products may
also be purified for sale.

• Product storage : Some inventory of finished product

must be held to match production with sales
• Provision for product packaging and transport will also be
needed, depending on the nature of the product

• Liquids will normally be dispatched in drams and in bulk

tankers (road, rail and sea), solids in sacks, cartons or
bales.The stock held will depend on the nature of the
product and the market.
• Ancillary Process: In addition to the main process stages shown in Figure
above, provision will have to be made for the supply of the services
(utilities) needed; such as, process water, cooling water, compressed air,
steam

• Facilities will also be needed for maintenance, fire fighting, offices and
other accommodation, and laboratories.
• Continuous process are designed to operate 24 hours a day and 7
days a week, throughout the year.

• Some down time will be allowed for maintenance and, for some
processes, catalyst regeneration. The plant attainment; that is, the
percentage of the available hours in a year that the plant operates,
will usually be 90 to 95%.
• Attainment % = (hours operated/8760)*100.

• Batch processes are designed to operate intermittently. Some, or all,

the process units being frequently shut down and started up.

• Continuous processes will usually be more economical for large scale

production. Batch processes are used where some flexibility is
wanted in production rate or product specification.
• Code: A code is a standard that has been adopted by one or more governmental
bodies and has the force of law, or when it has been incorporated into a business
contract
• Standard: A standard can be define as a set of technical definitions and guidelines-
“how to” instructions for manufactures and designers.
• Following codes and standards will assure safety, economic and will be tedious

• In engineering practice codes an standards cover

1. Materials, properties and composition.
2. Testing procedures for performance, composition and quality.
3. Preferred sizes, for example, tubes, plates, sections.
4. Design methods, inspection, fabrication.
5. Codes of practice, for plant operation and safety.

Standards generally followed across the globe:

ASME: American society of mechanical engineers
ASTM: American society for testing materials.
ISO: International Organization for standardization.
ANSI: American National Standard Institute
API: American Petroleum Institute.
BSI : British Standard Institute.
TEMA: Tubular Exchanger Manufacturers Association
• Design should have a specific objective , a need, and by
developing and evaluating possible designs, we arrive at best
design for the specific objective.

• Constraints narrow down the best possible design, It can be

classified as:
•External constraint : constraints that are beyond the designers
influence.
• Ex: safety regulations, physical laws, resources, standards and
codes,government controls, economic constraints.

• Internal constraint : under the influence of designer,

Ex: Choice of process, choice of process conditions, materials,
equipment and time.
Design process

1. Design objective: (need)

A designer is creating a design for an
article, or a manufacturing process to
fulfill a particular need.
A designer should differentiate between
real need and wants. i.e. must have and
should have.
The wants are those parts of the initial
specification that may be thought
desirable, but which can be relaxed if
required as the design develops.
 2. Process Flow
Diagram (PFD)

PROCESS
DIAGRAMS

4. Piping and 3. Process equipments

Instrumentation symbol and
Diagram (P&ID) numbering
 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.
 Mixed Gas
Toluene, C7H8 2610 kg/hr
10,000 kg/hr

Reactor Gas Separator Benzene, C6H6

C6H6
8,210 kg/hr
CH4
Hydrogen H 2
820 kg/hr C7H8
Mixed Liquid

75% Conversion of
Toluene

Reaction : C7H8 + H2 C6H6 + CH4

Block Flow Diagram for the Production of Benzene
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 BFD for these processes.
CH3CH2OH H2SO4 CH2=CH2 + H2O

CH2=CH2 + H2 CH3CH3
Ni
Hot water
out
Ethylene, Ethylene liq.
CH2CH2 (g) CH2CH2 (l)

Ethanol,

C2H5OH Cold Ethane,

CH2CH 2
Reactor 1 water in Reactor 2 CH3CH3
H2SO4 H 2O Distillation Hydrogen,
column H2 Ni
H2O
Ammonia-air mixture is feed to the bottom stream of an
absorber with flow rate of 10L/min. Water then feed to the
upper stream of the same absorber with desired flow rate of
5L/min. There are two outputs from the absorber, upper stream
is insoluble NH3 and bottom stream is NH3-Water mixture. This
NH3-water mixture then feed up to a batch distillation column.
The column produces ammonia gas as a top product which this
product then will be condensate with a condenser to produce
liquid ammonia. Develop Block Flow Diagram (BFD) for
this process.
Ammonia-air mixture is fed to the bottom stream of an absorber with flow rate of 10L/min.
Water is fed to the upper stream of the same absorber with desired flow rate of 5L/min.
There are two outputs from the absorber where upper stream is insoluble NH3 and bottom
stream is NH3-Water mixture. This NH3-water mixture then fed to a batch distillation
column. The column produces ammonia gas as a top product which this then will be
condensed with a condenser to produce liquid ammonia. Develop Block Flow Diagram
(BFD) for this process.
Hot water
out
Insoluble
ammonia Ammonia
liquid
Water 5 L/min
Ammonia gas Condenser

Batch
Absorber Distillation
Cold water
in

Ammonia-water mixture
Ammonia-air mixture 10 L/min
 Process Flow
Diagram (PFD)

PROCESS
DIAGRAMS

Process equipments Piping and

symbol and Instrumentation
numbering Diagram (P&ID)
 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.
1. Major Pieces Of
Equipment

PFD

4. Basic Control 3. Process Flow

Loops Streams
1. Major Pieces Of
Equipment

PFD

4. Basic Control 3. Process Flow

Loops Streams
PFD will contain the following information:-
1.All major pieces of equipment (descriptive
name, unique equipment no.), pumps and valves.

2.All the utility streams supplied to major

equipments such as steam lines, compressed air
lines, electricity, etc.
 Stream Numbering and Drawing

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

- Horizontal lines are dominant.

Yes No No
 Conventions Used for Identifying 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 Additional description of
equipment given on top of PFD
Supplemental Information

 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

Stream Information - Flag

600 Temperature
300

3 8 24 Pressure
9
6 7 10.3
1 10 Mass Flowrate

600 108
24 Molar Flowrate

2 5 12
Gas Flowrate

4 11 Liquid
Flowrate
24
13
 Stream Information - Full stream data:

Stream 1 2 3 4 5 6 7 8 9 10
Number
Temperature 25.0 35.0 35.0 35.0 35.0 60.3 41 38 54.0 45.1
(oC)
Pressure (psi) 28 32.2 31.0 31.0 30.2 45.1 31.3 24.0 39.0 2.6

Vapor fraction

Mass flow 10.3 13.3 0.82 20.5 6.41 20.5 0.36 9.2 20.9 11.6
(tonne/hr)
Mole flow 108 114.2 301.0 1204.0 758.8 1204.4 42.6 1100.8 142.2 244.0
(kmol/hr)
 R-100 P-100 T-100 E-100 P-101 R-101
Reactor Pump Distillation Column Condenser Pump Reactor

Hot water
out

Ethylene E-100 Ethylene liq.

6
V-104

Cold
25 T-100 water in V-106
CV-100 CV-101
28 V-105
Ethanol
1 5 20
H2SO4 V-101 V-102
4 38 Hydrogen
V-100
V-103 Ni
9
V-107
R-100
Ethane
3 8
R-101
2 35 10
35 31.0 7 H2O
32.2 P-101

P-100

Stream Number 1 2 3 4 5 6 7 8 9 10
Temperature (oC) 25.0 35.0 35.0 35.0 35.0 60.3 41 38 54 45.1
Pressure (psi) 28 32.2 31.0 31.0 30.2 45.1 31.3 24.0 39 2.6
Vapor fraction
Mass flow (tonne/hr) 10.3 13.3 0.82 20.5 6.41 20.5 0.36 9.2 20.9 11.6
Mole flow (kmol/hr) 108 114.2 301.0 1204.0 758.8 1204.4 42.6 1100.8 142.2 244.0
 R-100 P-100 T-100 E-100 P-101 R-101
Reactor Pump Distillation Column Condenser Pump Reactor
Hot water
out

Ethylene E-100 Ethylene liq.

6
V-104
Cold water in
LIC
25 T-100
CV-101
V-106
CV-100
28 V-105
Ethanol
1 5 20
V-101 V-102
H2SO4
4 38 Hydrogen
V-100
V-103 Ni
9
R-100 V-107
Ethane
3 35 8
R-101
2 10
35 31.0 7 H2O
32.2 P-101 LIC
P-100

Stream Number 1 2 3 4 5 6 7 8 9 10
Temperature (oC) 25.0 35.0 35.0 35.0 35.0 60.3 41 38 54 45.1
Pressure (psi) 28 32.2 31.0 31.0 30.2 45.1 31.3 24.0 39 2.6
Vapor fraction
Mass flow (tonne/hr) 10.3 13.3 0.82 20.5 6.41 20.5 0.36 9.2 20.9 11.6
Mole flow (kmol/hr) 108 114.2 301.0 1204.0 758.8 1204.4 42.6 1100.8 142.2 244.0
A/B Letter
Example

Hot water
out Hot water
out
Ethylene
Ethylene

Ethylene liq.
Cold
water in Cold Ethylene liq.
Ethanol water in
Ethanol
H2SO4 Hydrogen Ethane H2SO4 Hydrogen Ethane
Ni
Ni
H2O H2O

P-100 A/B P-100 A

P-100 B

In Real Plant
In PFD
• Piping and Instrumentation Diagram(P&ID) also called as
mechanical flow diagram.

• They do not show any operating conditions, or composition or

flow quantities but they do show all major as well as minor
equipment realistically than on process flow sheet.

• Systematic numbering of process equipment, pipes, pumps,

valves auxiliary equipment(side glass, level indicators, control
loops).

• Presents mechanical type details to mechanical engineers,

electrical engineers, instrumentation engineers.
 DIAGRAM (P&ID)
Instrumentation Symbology
Conventions for P & I Diagram

2. An id number, an identifier of the material of construction,

diameter and insulation requirements for each line.
3. Direction of flow.
4. Identification of main process and start-up lines.
5. All instrumentation, control and interlock facilities with
indication of action on instrument air failure.
6. Key dimensions or duties of all equipments.
7. Operating and design pressures and temperatures for vessels
and reactors.
8. Equipment elevations.
9.Set pressure for relief valves.
10.Drainage requirements.
• Gives utility information e.g., steam , cooling water ,
dowtherm (HT fluid), compressed air, chilled water. Etc..