Lecture#4:

Computer Aided Process Design

B.Tech 7th Sem. Chemical Engineering
Dr. Sukanta Dash
Department of Chemical Engineering
Pandit Deendayal Energy University

Reference book: Chemical Process Design and Simulation by Juma Haydary, A Joint Publication of the
American Institute of Chemical Engineers and John Wiley & Sons, Inc.

Development of Process Flow Diagrams

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• After the preparation of a simplified PFD and the collection of all necessary data, process
simulation with different scenarios can be realized.
• Based on the simulation results and their comparison with operational data and analysis of
different scenarios, the process modification can be suggested.

Development of Process Flow Diagrams

Development of a PFD for a design task usually starts with very simple diagrams with no
heat exchanger networks, reactor kinetic models, material, or heat integration.

After calculating these simplified schemes and gaining the knowledge on the
process background, the schemes can be improved by including two side heat exchangers,
reactor kinetic models, and material and energy recycling streams.

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 FEED: Front End Engineering Design

FEED (Front End Engineering Design) means Basic Engineering which is

conducted after completion of Conceptual Design or Feasibility Study. At this stage,
before start of EPC (Engineering, Procurement and Construction), various studies
take place to figure out technical issues and estimate rough investment cost.
 Process Diagrams
Block Flow Diagram (BFD) : simple representation of the process by major unit
operations connected with streams.

The other two major types of process diagrams are used by the chemical industry to
represent a chemical plant:

1. Process flow diagram (PFD): This shows how the process units are connected
and how the process works. Various symbols are used for each unit operation.
Pipes are indicated by lines connecting the units.

2. Process or piping and instrumentation diagram (P&ID): This is the most

detailed process diagram. Apart from streams, unit operations and processes,
this shows the various sensor, control systems, and final control elements. It
uses symbols and circles to represent how they are connected.
 Example of a Block Flow Diagram

Production of Benzene from Toluene and Hydrogen

Example of a Block Flow Plant Diagram

Production
of Higher
Alcohol
fuels from
Coal
 Example of a Process Flow Diagram

Production of Benzene from Toluene and Hydrogen

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 P&ID EXAMPLE

P&ID
of
Benze
ne
distilla
tion

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Process Diagram Symbols
The symbols used are not universal and have changed over time.
They are used in a flow diagram as follows:

Manual valve:

Control valve:

Solenoid valve:

Check valve: Arrow points in direction of flow

Relief valve:
 Process Diagram Symbols

Rupture disc: Furnace:

Pump:

Agitator:
Flowmeter:

Vessel: Packed column:

Heat exchanger: Distillation column:

Process Instrumentation Lettering
The tag identification lettering is shown in the following table:
Process
instrumentation has
First Letter Succeeding Letters
tags that consist of Measured or
letters and numbers Initiating Readout Output
placed within or near Variable Modifier Function Function Modifier
the instrument to A Analysis

identify the type and C Control

function. D Differential
F Flow rate Ratio
The following tag H Hand High
identifies this I Current Indicate
equipment as a TRC = L Level Low
temperature recording P Pressure,
controller and is vacuum
associated with control Q Quantity Totalizer
loop 100. S Safety Switch
T Temperature Transmit
V Vibration Valve,
damper
Z Position Actuator
Process Instrumentation Lettering
Typical examples for chemical plants for these tags are
shown here:

TI: Temperature Indicator

TR: Temperature Recorder
TT: Temperature Transmitter
TC: Temperature Controller
TRC: Temperature Recorder Controller
LT: Level Transmitter
LIC: Level Indicator Controller
FC: Flow Controller
FT: Flow Transmitter
FRC: Flow Recorder Controller
PT: Pressure Transmitter
Process Instrumentation Lettering
A line in the middle of the tag circle denotes the location: No
line: The instrument is mounted in the field near the process.

Solid line: The instrument is mounted in the control room and is

accessible to the operator.

Dashed line: The instrument is mounted out of sight and is not

accessible by the operator.
Process Instrumentation Lettering
There are also symbols to identify how the instruments are connected
to each other and which type of signal is being used (electrical,
pneumatic).

Piping: thick line

Process connection: thin line Electrical

signal: dashed line Pneumatic signal:

Example of small unit Process
Diagrams
PFD Drawing Symbols

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Symbols for Stream Identification

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Many aspects of The Process Flow Diagram

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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 Process and Utility Streams

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 Stream Information - Flags

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 PFD 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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 Mass and energy Balance From PFD
In Industrial word: Heat and Material Balance (HMB)

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. 1204. 42.6 1100. 1247. 142.2
758.8
4 4 8 0
Component Mole Flow
(kmol/h)
Hydrogen 0.0 0.0 286.0 25.2 0.02
735.4 449.4 735.4 651.9 652.6
Methane 0.0 0.0 15.0 16.95 0.88
317.3 302.2 317.3 438.3 442.3
Benzene 0.0 1.0 0.0 7.6 6.6 7.6 0.37 106.3
9.55 116.0
Toluene 143.2 0.0 0.7 0.04 36.0 35.0
108.7 144.0 144.0 1.05
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Basic Control Loops

 Often the basic control loops (those

involving maintaining material balance
and reactor controls) are include on the
PFD; instrumentation and other control
loops are not shown in PFD

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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

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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 Look at V-102 on P&ID

V-102 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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 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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