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Chapter 2 - Process Plant Design Part III v2

The document discusses process plant design, specifically the production of ethane from ethanol. It involves ethanol being fed into a continuous reactor with sulfuric acid as a catalyst to produce ethylene, which is then separated via distillation. Ethylene is condensed and ethylene is hydrogenated in another reactor using nickel as a catalyst to produce the final product of ethane. The document also discusses process flow diagrams, piping and instrumentation diagrams, procurement of main apparatus, and requesting quotations for the design process.

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Brandeice Barrett
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© © All Rights Reserved
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Download as PPTX, PDF, TXT or read online on Scribd
162 views

Chapter 2 - Process Plant Design Part III v2

The document discusses process plant design, specifically the production of ethane from ethanol. It involves ethanol being fed into a continuous reactor with sulfuric acid as a catalyst to produce ethylene, which is then separated via distillation. Ethylene is condensed and ethylene is hydrogenated in another reactor using nickel as a catalyst to produce the final product of ethane. The document also discusses process flow diagrams, piping and instrumentation diagrams, procurement of main apparatus, and requesting quotations for the design process.

Uploaded by

Brandeice Barrett
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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BSB3503 - Biomanufacturing

CHAPTER 2
Process Plant Design – Part III

Author: Nurul Azyyati Sabri


Co-Author / Editor: Rama Yusvana
Faculty Industrial Sciences & Technology
[email protected]
Basic flow diagram
Production of Ethane from Ethanol
Ethanol is feed to continuous reactor with presence of Acid Sulphuric
catalyser 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.
Production of Ethane from Ethanol
Process flow diagram (PFD)

• Showing the connectivity of all the streams of materials and


the equipment
• PFD will contains the following information:-
- All equipments : such as pumps and valves, compressors,
columns.
- All utility streams such as steam lines, compressed air lines,
electricity, etc.
- All process flow streams: identified by a number, process
condition, chemical composition.
- Basic control loops: showing the control strategy used
• Using software – AUTOCAD and VISIO
• Developed special for process engineering
• Typical component data in the software:
– Instrument ID
– Drawing number
– Dimensions
The Process Flow Diagram (PFD)

Process Unit Symbology

Symbol Description

Heat exchanger

H2O Water cooler

S Steam heater

Cooling coil
The “Process Flow Diagram” (PFD)
Process Unit Symbology

Symbol Description

Heater coil

Centrifugal pump

Turbine type compressor

Pressure gauge
The “Process Flow Diagram” (PFD)

Process Unit Symbology

Symbol Name Description

Stripper Convert liquid mixture into gas


phase

Absorber Convert mixture gas into liquid


phase
The “Process Flow Diagram” (PFD)

Process Unit Symbology

Symbol Name Description

Distillation Separate liquid into


miscellaneous component
column fractions.

Liquid mixer Mix liquid components.


or
The ”Process Flow Diagram” (PFD)

Process Unit Symbology

Symbol Name Description

Reaction Location of chemical process or


reaction occurs
chamber

Horizontal tank Store liquid or gas.


or cylinder
The “Process Flow Diagram” (PFD)

Process Unit Symbology


Symbol Name Description

Boiler Heating purposes.

Centrifuge Physically separated liquid


mixture (exp: oil-liquid)
The “Process Flow Diagram” (PFD)

Valve Symbology
Symbol Name

Gate Valve

Globe Valve

Ball Valve

Check Valve

Butterfly Valve
The “Process Flow Diagram” (PFD)

Valve Symbology
(a)
Symbol Name

Relief Valve (d)


(b)
Needle Valve (a)

3-Way Valve (c) (c)


(d)

Angle Valve (e)


(e)

Butterfly Valve (b)


The “Process Flow Diagram” (PFD)

PFD will contains the following information:-


- All process flow streams: identification by a
number, process condition, chemical composition.
Line Numbering and Method for Drawing
- Generally numbers made from left to right.
- Horizontal lines cuts or break vertical line.

Yes No No
Example
The Process Flow Diagram (PFD)

Stream Description

- Mainly reactors and towers, etc.

 Use Flags when necessary

 Can include full stream data


The Process Flow Diagram (PFD)
Example
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
Example
The Process Flow Diagram (PFD)
• PFD usually also contains the following
information:-
• Basic control loops: showing the control
system in place.
Piping and instrumentation diagrams

• The drawing is started after the order


placement and approximately at the same
time to the procurement of the components.
• The information given is subdivided into basic
information.
• Information includes:
– Appliances and machinery
– Pipes or means of transport (e.g. moving belts)
– Valves and fittings
– Information on dimension, nominal pressures
and material classification
– Any insulation, electric pipe heater, gradients &
materials
• Example:
– Simple pump group
– Atmosphere Vessel
– Pump unit with automatic flushing device
– Tubular heat exchanger
– Hydrochloric acid metering system
Example: Simple pump group
Main apparatus

• Steps in procurement of the main apparatus:


• 1) process-related design
– Applied knowledge of thermal, chemical, mechanical,
biological process engineering.
– Hydrodynamic: The reactor diameter and its height, Heat
exchangers, Design of compressors: thermodynamic
aspect
– All results recorded in technical data sheet
• 2) strength related design
– Calculation on wall thickness
• 3) production-related design
– Carried out within detail engineering
– Assigned to subcontractors
Layout

• Generally very complex


• Occur only after submission of P&I drawing –
within the detail engineering
Quotation

• A request for quotation (RFQ) is a standard


business activity inviting suppliers to bid
specific products or services.
• Include payment terms, quality level per item
or contract length etc.
• To receive accurate quotation, therefore it also
includes the full specifications of the
items/services.
Quotation

• The more detailed the specifications should


minimize potential problems regarding
products or services specification.
• Acting as legal binding documentation for the
suppliers.
• Best suited for products and services that are
as standardised to make each supplier's quote
comparable.

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