Module 3 (Process Flowsheet Development) (Autosaved)

Covenant University
KM. 10 Idiroko Road, Canaan Land, Ota, Ogun State, Nigeria
Department of Chemical Engineering
CHE 414: PRINCIPLES OF PLANT

DESIGN 1
DR O.A MAMUDU
ENGR (MRS) OLADIMEJI
Chemical Engineering Design

MODULE 3: PROCESS
FLOWSHEET DEVELOPMENT
Covenant University Department of Chemical Engineering-

Mamudu Angela, PhD.
Process Flowsheet Development
Objectives
How do we put together a combination of unit operations
that will convert the specified feeds into a desired
product?
How to read and design a process flow diagram
What can the flowsheet tell us about the costs of making

different products or using alternative feeds?
How to develop a flowsheet for revamp process
How to synthesize a flowsheet from an entirely new

process
How to review a flowsheet and check for completeness

and errors
Covenant University Department of Chemical Engineering-
Mamudu Angela, PhD.
Flowsheet
Key document in process design
Diagrammatic model of the process (arrangement of

equipment selected to carry out a process
Shows stream connection, stream flowrates, stream

compositions and operating conditions
Drawn up from material balances made over the

complete process and each individual unit
Facilitated by computer-aided flow-sheeting programs
Chemical Engineers use this tools as a primary means of

transmitting and recording process information

Importance of Flowsheets
Specialist design groups use it as the basis of their
design
Used by operating personnel's for preparing operating

manuals and operator training
During start up and subsequent operation, the flowsheet

forms a basis of comparison of operating performance
with design
During revamp process, the process flow diagram of

existing process serves as the basis
2007 G.P. Towler / UOP. For educational use in conjunction with

Sinnott & Towler Chemical Engineering Design only. Do not copy
What Does it Take to Make a Flowsheet?
Compressors Control
Reactors Instruments
Coolers
Mixers Pumps
Heaters Separations

Towler & Sinnott Chemical Engineering Design only. Do not copy
Flowsheet Presentation
Block Diagram
Simplest form of flow diagram
Shows rough idea of the overall process flow
structures
Each block represent a single piece of equipment or a
complete stage in a process
Used basically for showing simple processes
When used for complex processes, only principal
stages are shown
Made at the beginning of a process design for
orientation purposes or later as a summary of the
material balance of the process

Block Diagram
Block flow diagram of steam reforming process for

hydrogen
Block Diagram
Steam reforming process for hydrogen
Methane mixed with steam
Preheated in the convective section of the heater
Steam reforming takes place in the radiant section of
the heater
Water gas shift reaction takes place to produce more

hydrogen (lower temperature)
Further cooled while absorber removes CO2 formed

PSA separates hydrogen from carbon dioxide ;
unconverted methane and water vapour are recycled
Block Flow Diagrams
Cl2 A Recycle DCE

Chlorination
Ethylene C D VC
Pyrolysis Separation
B
Oxyhydro-
Oxygen
chlorination
Recycle HCl
Simple example vinyl chloride
Shows only overall structure of the process

Block Flow Diagram Example 2: Acrylic
Acid From Propylene by Catalytic Oxidation
First Stage Second Stage Absorbing Purification
Reactor Reactor Column Columns
Propylene
Waste Gas Acrylic Acid
Water
Air Waste

Example 3: Isopropyl Alcohol from
Propylene by Direct Hydration
Reactor Flash Recovery Dehydration IPA Lights Column
Separator Column Column Column Decanter
Propylene
Lights
Isopropyl Alcohol
Water
Water Treatment

Example 4: Caprolactam From Toluene
Toluene Oxidation
Benzoic Acid Hydrogenation
Toluene
Air Catalyst Hydrogen Catalyst Return
Steam Steam
Extraction and Purification
Nitrozation
Capro-
lactam
Ammonia
Oleum
Nitrosylsulphuric
Ammonium
Acid Water
Sulf ate
This is still a block flow, not a PFD, as it does not include

all process equipment
Block Flow Diagram
What should you look for when sketching a BFD?
Is this a batch or a continuous process?
What feeds are needed for the process & in what order should they
be mixed and added?
Are any feed pretreatment steps necessary?
What type of reactor will we use?
What are the separation alternatives?
Will these separations allow us to meet product quality
specifications?
What are the possible recycle and byproduct streams? Do they
require any further processing?

Exercise: Ethylene from Ethane
Ethylene can be made by:
C2H6 C2H4 + H2
The reaction is endothermic and is run in the presence of

steam (hence the process is called Steam Cracking),
without a catalyst at 870C.
The reactor products are rapidly quenched to about

550C to prevent secondary reactions
Sketch the block flow diagram

Steam Cracker Block Flow Diagram
Furnace Gasoline Acid Gas Demethanizer Acetylene
Column Removal Saturation
& Drying
H2
Ethylene
Hydrocarbon
feed stock
Steam
HP Steam
CH4 H2
Ethane
Pyrolysis Further
gasoline Distillation
Compression Cold Box Deethanizer C2 Splitter

Process Flow Diagram (PFD)
The material and energy balances
The sizing of the major equipment
Data include flow quantities, compositions, pressures,
temperatures, and so on
Location of every control valves
Piping and Instrumentation diagrams (P & ID)

Also called the Engineering Flow-sheet or Mechanical Flow-
sheet
Shows every mechanical aspect of the plant regarding the
process equipment and their interconnections except for
supporting structures and foundations.
Included are sizes and specification classes of all pipe lines, all
valves, and all instruments
Mainly used in detailed design and safety designs
PFD SYMBOLS
Several companies prefer to use their own standard
symbols
ISO 10628- presently the standard and used by most

European countries
Micrsoft Visio TM contains a library of PFD Icons

PFD SYMBOLS
PFD symbols for reactors, vessels, mixers, and

tanks.
PFD SYMBOLS
symbols for heat transfer equipment

PFD SYMBOLS
symbols for fluid-handling equipment

PFD SYMBOLS
PFD symbols for solids-handling equipment

PFD SYMBOLS
General PFD symbols used with other symbols

Separation Processes
Separation processes are needed for feed pretreatment,

product recovery and waste processing
Most separations are based on moving a component

from one phase to another and then segregating the two
phases
Driven by activity gradient as phases try to reach equilibrium
Affected by rates of mass transfer and heat transfer

Vapor-Liquid Separations
Flash Absorption
Single stage thermal Removal of vapor
& phase eqbm component using
non-volatile solvent
Distillation
Evaporation
Multiple stage separation
Single stage removal of
between identified light key
volatile solute or solvent
& heavy key components
Stripping
Fractionation Multi-stage removal
Separation of multicomponent of volatile solute
mixture into fractions by from solvent
boiling ranges (e.g. in oil
refining)
Example: Crude Oil Fractionation
Crude
Column
Overhead
Receiver First process in
oil refining
Recontact Stabilizer Sizes range

Drum from 10 to 850
To Flare
kbd
Consumes
0.8% of the
LPG energy content
of the oil
Kerosene
Charge Straight-run
Heater Sidecut
Strippers
Light Gas Oil Splitter products all
require further
processing
Steam
Steam Heavy Gas Oil Light
Crude
Oil Naphtha
Reduced Crude
Heavy
Naphtha

Example: Acid Gas Scrubbing
Treated Gas
Cooler Acid Gas
Water
Knock-Out
Amine
Drum
Amine Stripper
Absorber Filter
Lean Amine
Cooler
Flash Gas
Feed Gas
Lean/Rich
Exchanger
Water
Rich Flash Drum

Reboiler
For removal of H2S &/or CO2 from gases using solvents such as
methyldiethanolamine (MDEA)
Vapor-Vapor Separations
Membrane
Based on differences in relative
permeability of gases Absorption
Used for H2/CH4, CO2 removal, Using a liquid solvent
air separation in an absorber-
stripper loop
Used for acid gases,
drying, water wash
Adsorption
Adsorb components selectively on a solid
Regenerate sorbent by temperature swing
(TSA) or pressure swing (PSA)
Used for air separation, H2/CH4, most
separations involving low concentrations
Liquid-Liquid Separations
Decanting
Single stage thermal Mixer-Settler
& phase eqbm Single theoretical stage
extraction process
Often 2 or 3 stages are still
cheaper than a column
Extraction
Multi-stage
contacting of two Membrane
liquid phases Based on differences in relative
permeability of components
Membrane can be used to keep
two solvents from mixing

Fluid-Solid Separations
Cyclone
For bulk solids Driers
recovery from L or V Remove residual traces of
liquid from solid
Belt or rotary driers are
Centrifuge used in continuous plants
Enhanced gravity
separation, usually
from liquid Filter
Used for recovery of fine
material from L or V.
Crystallization Requires scraping or bag-house
Stirred tank designed to for continuous operation
have right residence time to
grow desired crystal size

Presentation of Information
Simplest Method
Flowsheet: polymer production.

Simplest Method
Tabulate data in blocks alongside the process stream lines
Only a limited amount of information can be shown
Difficult to make alterations or add additional
Better Method
Streamline numbered and data tabulated at the bottom of the
sheet
Alterations and additions can easily be made
Used by professional

Better Method
Flowsheet: simplified nitric acid process.

Better Method (Alternative)

Essential information for PFD
Stream composition, either:
the flow-rate of each individual component, kg/h, which is
preferred, OR
or the stream composition as a weight fraction.
Total stream flow-rate, kg/h.
Stream temperature, degrees Celsius preferred.
Nominal operating pressure (the required operating pressure).
Optional information
Molar percentages composition.
Physical property data, mean values for the stream, such as:
density, kg/m3 ,viscosity, Mn s/m2.
Stream name, a brief, one or two-word, description of the nature
of the stream, for example ACETONE COLUMN BOTTOMS.
Stream enthalpy, kJ/h.
Flow Sheet Layout
Sequence of the main equipment items follows that of
the proposed plant layout.
Equipment should be drawn approximately to scale
Ancillary items can be drawn out of proportion
Where many process units, several sheets may be

needed
Continuation of the process streams from one sheet to

another must be clearly shown. One method : those
lines which are continued over to another indicated by a
double concentric circle round the line number and the
continuation sheet number written below

Flow Sheet Layout
Table of stream flows and other data above or below the
equipment layout
Components listed down the left-hand side of the table
For long table repeat the list at the right-hand side
Stream line numbers should follow consecutively from

left to right of the layout
Process stream lines shown on the flow-sheet should be

numbered and the data for the stream give

Precision of Data
High precision not needed - at most one decimal
Flows should, however, balance to within the precision

shown
Small stream or component flow less than the precision

used can be shown to a greater number of places (if
necessary)
Imprecise small flows shown as TRACE not zero!.
Trace components, when specified as a process

constraint can be shown in parts per million, ppm.

Process Flow Development
Equipment Identification
A letter and some digits for general process control procedure
Easiest way is to use an initial letter to identify the equipment
followed by the digit to identify the particular piece R1 (First
Reactor), H2(second Heat Exchanger), C1(First column)
Computer Aided Diagram

Standard symbols representing the process equipment,
instruments and control systems held in files and called up as
required in Computer aided drafting
Limitation- the simulation may include dummy items that do not
physically exist
Limitation-may omit some equipment that is needed in the plant
but is not part of the simulation

Manual Flow Sheet Calculations
External constraints:
I. Product specifications possibly set by customer requirements.
II. Major safety considerations, such as flammability limits.
III. Effluent specifications set by government agencies.
Internal constraints:
I. The process stoichiometry, reactor conversions and yields
II. Chemical equilibria.
III. Physical equilibria, involved in liquid-liquid and gas/vapour-
liquid separations.
IV. Azeotropes and other fixed compositions.
V. Energy-balance constraints. Where the energy and material
balance interact, as for example in flash distillation.
VI. (vi) Any general limitations on equipment design

Basis for Flowsheet Calculation
90 to 95 per cent of the total hours in a year (8760)
Typically a value of 8000 hours per year
Scaling Factor

Use of design constraints to determine
stream flows and compositions
Reactors
Reactor yield and conversion specified (from literature or pilot
plant data). Material balance gives stream flows and
compositions
Chemical equilibrium. This holds true for fast reaction
Equilibrium stage
stream compositions calculated from the phase equilibrium data
for the components (a separation or mixing unit)
stage gas-liquid and liquid-liquid separators, such as
quench towers, partial condensers and decanters
particularly useful if one component is essentially non-
condensable and can be used as a tie substance

Use of design constraints to determine
stream flows and compositions
Fixed stream compositions
If sufficient design variables are fixed by external constraints, or
by the designer, then the other stream flows round a unit will be
uniquely determined
Combined heat and material balances

often possible to make a material balance round a unit
independently of the heat balance
sometimes simultaneous heat and mass balances must be made
simultaneously for instance, in flash distillation or partial
condensation

Effect of Reactor Conversion and
Yield

Effect of Reactor Conversion and
Yield

Yield- Measure of the performance of a reactor or plant

Excess Reagent

Reasons for Recycles
Recycle streams are used for a wide range of purposes,
including:
Recovery of unreacted feeds
React byproducts to extinction
Control reactor T by recycling inert material

Recycle Design Issues
What purity is needed for the recycle stream?
Will anything in the recycle damage the catalyst?
What species will accumulate in the recycle?
What concentrations will accumulated species reach?
What is the cost of recycle vs. once-through operation?

Recycle & Purge
Purge
Feed Product
A purge stream is often withdrawn from a recycle to prevent

contaminants from accumulating
The purge flow rate must be set high enough to give the
desired concentration of contaminants in the recycle stream
More purge flow = lower contaminant concentration
But too much purge is expensive, so theres a trade-off
If purge cost is excessive, consider adding a separation
Remember to add purge streams to process simulation

models otherwise recycles will not converge

Exercise: UOP Aromatics Complex Block
Flow Diagram: Spot the Recycles

Exercise: UOP Aromatics Complex
Block Flow Diagram

Flow Sheet Calculations

TUTORIAL
Sinott, R.K. (2005). Chemical Engineering
Design , 4th Edition, Volume 6 , Elsevier
Butterworth- Heinemann
Study Examples 4.2, 4.3, 4.4

Computer Aided Flow Sheeting
Two types : Full simulation programs and simple material
balance program
Full Simulation Programs

Powerful computing facilities
Rigorous simultaneous heat and material balance
Preliminary equipment design, producing accurate and detailed
flowsheet
Not justifiable for early stage of a project
Simple Material Balance Program

Aid to manual calculation
Enable preliminary flowsheet to be quickly and cheaply provided

Full Steady State Simulation
Program

Full Steady State Simulation
Program
Pros and Cons
Husain (1986) Westerberg et al. (1979)
Wells and Rose (1986) Crowe et al. (1971)
Leesley (1982) Panelides (1988)
Bender (1980)
Mah and Seider (1980)

Approaches

Limitation of Modular
Cannot stimulate dynamic, time dependent behavior of a process
Computational difficulties due to the iterative method used to solve
recycle problems and obtain convergence
Limitation of Equation Based

Require appreciably more computing power than steady state
simulation
Dont experience problem of recycle convergence
More time demanding
The principle advantage of equation based dynamic

simulation is their ability to model the unsteady state
conditions that occur during start up and trouble shooting.


Main executive programs
Controls and keep track of the flowsheet calculations
Shows the flow of information to and from the sub-routines
Library of equipment performance

Stimulate equipment
Enable output streams to be calculated from information on inlet streams
Thermodynamics subroutines
Calculation of vapour liquid equilibria and steam enthalpies
Physical Property
How comprehensive the physical property data bank will determine the
level of sophistication
Cost Data files

Estimation of equipment capital cost and operating cost
Shows alternative process scheme where quick economic comparison can be made

Information Flow Diagram
Directed Graph
basic process flow diagram, which shows the sequence of unit operations
and stream connections transformed into an information flow diagram
Each block represents a calculation module in the simulation program
Units in which no change of composition, or temperature or pressure,
occurs are omitted from the information flow diagram.
Other operations not shown on the process flow diagram as actual pieces
of equipment, but which cause changes in the stream compositions, such
as mixing tees, shown.
The lines and arrows connecting the blocks show the flow of information
from one subprogram to the next.
The calculation topology defined by the information diagram is transformed
into a numerical form suitable for input into the computer, usually as a
matrix

Process Flowsheet Development
Summary
The flowsheet shows the sequence of unit operations

from feed treatment to product storage
Experienced designers usually start from existing

flowsheets
Something similar to the process that is envisioned, a patent or other reference
This saves time and money and reduces commercialization risk
Process simulation is usually carried out hand in hand

with flowsheet development
Testing different flowsheet concepts
Developing mass and energy balances
Sizing and costing equipment for process optimization

Questions ?


Module 3 (Process Flowsheet Development) (Autosaved)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Module 3 (Process Flowsheet Development) (Autosaved)

Uploaded by

Copyright:

Available Formats

Covenant University

KM. 10 Idiroko Road, Canaan Land, Ota, Ogun State, Nigeria

Department of Chemical Engineering

CHE 414: PRINCIPLES OF PLANT

Chemical Engineering Design

Covenant University Department of Chemical Engineering-

How to read and design a process flow diagram

What can the flowsheet tell us about the costs of making

How to develop a flowsheet for revamp process

How to synthesize a flowsheet from an entirely new

How to review a flowsheet and check for completeness

Diagrammatic model of the process (arrangement of

Shows stream connection, stream flowrates, stream

Drawn up from material balances made over the

Facilitated by computer-aided flow-sheeting programs

Chemical Engineers use this tools as a primary means of

Chemical Engineering Design

Used by operating personnel's for preparing operating

During start up and subsequent operation, the flowsheet

During revamp process, the process flow diagram of

2007 G.P. Towler / UOP. For educational use in conjunction with

2012 G.P. Towler / UOP. For educational use in conjunction with

2007 G.P. Towler / UOP. For educational use in conjunction with

Block flow diagram of steam reforming process for

Water gas shift reaction takes place to produce more

Further cooled while absorber removes CO2 formed

Cl2 A Recycle DCE

Simple example vinyl chloride

Shows only overall structure of the process

2012 G.P. Towler / UOP. For educational use in conjunction with

2012 G.P. Towler / UOP. For educational use in conjunction with

2012 G.P. Towler / UOP. For educational use in conjunction with

Air Catalyst Hydrogen Catalyst Return

This is still a block flow, not a PFD, as it does not include

2012 G.P. Towler / UOP. For educational use in conjunction with

Ethylene can be made by:

The reaction is endothermic and is run in the presence of

The reactor products are rapidly quenched to about

Sketch the block flow diagram

2012 G.P. Towler / UOP. For educational use in conjunction with

Compression Cold Box Deethanizer C2 Splitter

2012 G.P. Towler / UOP. For educational use in conjunction with

Piping and Instrumentation diagrams (P & ID)

ISO 10628- presently the standard and used by most

Micrsoft Visio TM contains a library of PFD Icons

2007 G.P. Towler / UOP. For educational use in conjunction with

PFD symbols for reactors, vessels, mixers, and

symbols for heat transfer equipment

2007 G.P. Towler / UOP. For educational use in conjunction with

symbols for fluid-handling equipment

PFD symbols for solids-handling equipment

2007 G.P. Towler / UOP. For educational use in conjunction with

General PFD symbols used with other symbols

2007 G.P. Towler / UOP. For educational use in conjunction with

Separation processes are needed for feed pretreatment,

Most separations are based on moving a component

2012 G.P. Towler / UOP. For educational use in conjunction with

Recontact Stabilizer Sizes range

2012 G.P. Towler / UOP. For educational use in conjunction with

Rich Flash Drum

2012 G.P. Towler / UOP. For educational use in conjunction with

2012 G.P. Towler / UOP. For educational use in conjunction with

Flowsheet: polymer production.