Introduction

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Department of Oil and Gas processing

THE NATURE OF PROCESS DESIGN

A Creative Activity

[ Example ]
CH3
+
Toluene

H2
Hydrogen

+
Benzene

CH4

Methane

The most effective way of

communicating information
about a process is through
the use of flow diagrams.
Block Flow Diagram (BFD)
Process Flow Diagram (PFD)
Piping and Instrumentation Diagram
(P&ID)

Toluene
(10,000 kg/h)

Hydrogen
(820 kg/h)

Reactor

Gas
Separator

Mixed Gas
(2,610 kg/h)

Benzene
(8,210 kg/h)
Conversion
75% Toluene

Mixed Liquids

Toluene
Reaction : C7H8 + H2 = C6H6 + CH4
Figure 1.1 Block flow process diagram for the production of benzene
Toluene and hydrogen are converted in a reactor to produce benzene and methane.The
reaction does not go to completion, and excess toluene is required. The noncondensable
gases are separated and discharged. The benzene product and the unreacted toluene are
then separated by distillation. The toluene is then recycled back to the reactor and the
benzene removed in the product stream.

Table 1.1 Conventions and Format Recommended for Laying out a

Block Flow Process Diagram

1. Operations shown by blocks.

2. Major flow lines shown with arrows giving direction of flow.
3. Flow goes from left to right whenever possible.
4. Light stream (gases) toward top with heavy stream (liquids and solids) toward
bottom.
5. Critical information unique to process supplied.
6. If lines cross, then the horizontal line is continuous and the vertical line is broken.
7. Simplified material balance provided.

Process Flow Diagram (PFD)

A PFD includes the following items:
1. major equipments;
2. principal flow route and control involved from raw
material feed to final product;
3. key temperature and pressure corresponding to
anticipated normal operation;
4. material flow rates and compositions;
5. design duties and sizes of major equipments.

Table 1.2 Conventions Used for Identifying Process Equipment

Process Equipment

Supplemental Information

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

Table 1.3 Conventions for Identifying Process and Utility Streams

Process Streams
All conventions shown in Table 1.1 apply.
Diamond (square) symbol located in flow lines.
Numerical identification (unique for that stream) inserted in diamond (square).
Flow direction shown by arrows on flow lines.

Utility Streams
lps
mps
hps
htm
cw
wr
rw
rb
cs
ss
el
ng
fg
fo
fw
These

Low Pressure Steam: 3-5 barg (sat)

Medium Pressure Steam: 10-15 barg (sat)
High Pressure Steam: 40-50 barg (sat)
Heat Transfer Media (Organic): to 400C
Cooling Water: From cooling tower 30C returned at less than 45C+
River Water: From river 25C returned at less than 35C
Refrigerated Water: In at 5C returned at less than 15C
Refrigerated Brine: In at -45C returned at less than 0C
Chemical Waste Water with high COD
Sanitary Waste Water with high BOD, etc.
Electric Heat (specify 220, 440, 660V service)
Natural Gas
Fuel Gas
Fuel Oil
Fuel Water

pressure are set during the preliminary design stages and typical values vary within the ranges
shown.
+Above 45C, significant scaling occurs.

Table 1.4 Information Provided 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/s)

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

Table 1.6 Equipment Descriptions for PFD and P&IDs

Equipment Type
Description of Equipment
Towers
Size (height and diameter), Pressure, Temperature
Number and Type of Trays
Height and Type of Packing
Materials of Constructions
Heat Exchangers
Type: Gas-Gas, Gas-Liquid, Liquid-Liquid, Condenser, Vaporizer
Process: Duty, Area, Temperature, and Pressure for both streams.
No. of shell and Tube Passes
Materials of Construction: Tubes and Shell
Tanks
See vessels
Vessels
Hight, Diameter, Orientation, Pressure, Temperature, Materials of Construction
Pumps
Flow, Discharge Pressure, Temperature, P, Driver Type, Shaft Power, Materials of Construction
Compressors
Actual Inlet Flow Rate, Temperature, Pressure, DrverType, Shaft Power,
Materials of Construction
Heaters (fired)
Type, Tube Pressure, Tube Temperature, Duty, Fuel, Material of Construction
Others
Provide Critical Information

Piping and Instrumentation Diagram

(P&ID)
1. All process equipments and pipings required for start-up, shut-down,
emergency and
normal operation of the plant, including valves, blinds, etc.
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.
11.Special notes on piping configuration as necessary, e.g. gravity
drainage.

Table 1.8 Exclusions from Piping and Instrumentation Diagram

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

Table 1.9 Conventions in Constructing Piping and Instrumentation Diagrams

For Equipment - Shown Every Piece Including
Spare units
Parallel units
Summary details of each unit
For Piping - Include All Lines Including Drains, Sample Connections and Specify
Size (use standard sizes)
Schedule (thickness)
Materials of construction
Insulation (thickness and type)
For Instruments - Identify
Indicators
Recorders
Controllers
Show instrument lines
For Utility - Indentify
Entrance utilities
Exit utilities
Exit to waste treatment facilities

Activities of Process Design

(1)Synthesis
The step where one conjectures the building blocks and
their interconnections to create a structure which can meet
the stated design requirements.
(2)Analysis (Simulation)
The activity of modeling and then solving the resulting
equations to predict how a selected structure should behave
if it were constructed.
(3)Evaluation
The activity of placing a worth on the structure where the
worth might be its cost, its safety, or its net energy
consumption.
(4)Optimization
The systematic searching over the allowed operating
conditions to improve the evaluation as much as possible.

Parameter
structure

Process Synthesis
A design task where one conjectures the building
blocks and their interconnections to create a structure
which can meet the stated design requirements.

IMPORTANCE OF PROCESS STRUCTURE

(1) Recycle

AP

or

(2)separation Sequence ?
A (propane)
A

B (1-Butene)
B

A
AB

or

ABC
BC

ABC

(3)Heat Recovery ?

or
H

C(n-Butane)

B
C

Feed
Streams

PROCESS ?

Product
Streams

(a) Process design starts with the synthesis of a process to convert raw

materials into desired products.

Feed
Streams

PROCESS

Product
Streams ?

(b) Simulation predicts how a process would behave if it was constructed.

Figure 1.1 Synthesis is the creation of a process to transform feed streams

into product streams. Simulation predicts how it would behave if it was
constructed.

Reactor
Separation and
Recycle System
Heat Exchanger
Network

Utilities

Figure 1.6 The onion model of

process design. A reactor design in
needed before the separation and recycle
system can be designed, and so on.
(From Smith and Linnhoff, Trans.
IChemE, ChERD, 66:195, 1988;
reproduced by permission of the
Institution of Chemical Engineers.)

Example Hydrodealkylation of Toluene

CH3

CH4

H2
Toluene

Benzene

H2
Benzene

Diphenyl

A HIERARCHICAL APPROACH

Toluene + H2 Benzene + CH4

2 Benzene
Diphenyl + H2
1150 F 1300 F
500 psia

Liquid
recycle
H2, CH4

Benzene
product
Purge
compressor
Gas
recycle

Diphenyl

furnace

Reactor

CW

FIGURE 1.2-2
Hydrodealkylation of toluene; maximum energy recovery.

ENERGY INTEGRATION

Flash
hh

H2, feed

Toluene
feed

Vapor Recovery System

H2 Feed

Purge

compressor

Reactor

Toluene
Feed

Flash
Drum
Benzene

Toluene
Recycle

Distillation Train

Stablizer

Benzene Col.

Toluene Col.

Diphenyl

ALTERNATIVES OF DISTILLATION TRAIN

(1) Recycle Diphenyl
H2, CH4

Benzene

(2)
Feed
Toluene
(recycle)

Diphenyl

(3)

H2
CH4

Benzene

Toluene
(recycle)

Diphenyl

ALTERNATIVES OF VAPOR RECOVERY

SYSTEM
(1) Condensation;
(2) Absorption;
(3) Adsorption;

(4) Membrane.

Vapor recovery
system

H2 , CH4

Reactor
system

Purge
H2 , CH4

Phase
split

Toluene

Liquid separation
system

Benzene

Dipheny1

Simplified Flowsheet for the Separation System

Gas recycle

H2 , CH4
Toluene

Purge
H2 , CH4
Benzene

Reactor
system

Separation
system
Dipheny1

Toluene recycle

Recycle Structure of the Flowsheet

Purge
H2 , CH4

H2 , CH4

Benzene

Toluene

Dipheny1

Input-Output Structure of the Flowsheet

Hierarchy of decisions
1. Batch versus continuous
2. Input-output structure of the flowsheet
3. Recycle structure of the flowsheet
4. General structure of the separation system
a. Vapor recovery system
b. Liquid recovery system
5. Heat-exchanger network Ch.6, Ch.7, Ch.16

Ch. 4
Ch.5