CHEMICAL PROCESS DIAGRAM

Chemical Process Diagram

SCOPE:
Students will be able to know:-

Type of chemical process diagram

- Block Flow Diagram (BFD)
- Process Flow Diagram (PFD)
- Piping and Instrumentation Diagram (P&ID)

How to read and draw BFD, PFD and P&ID

Process equipments symbol and numbering

 Chemical Process Diagram

3 Levels of Diagram
-Block Flow Diagram (BFD)
-Process Flow Diagram (PFD)

-Piping and Instrumentation Diagram (P&ID)

 The Block Flow Diagram (BFD)

BLOCK FLOW DIAGRAM (BFD)

 The Block Flow Diagram (BFD)

Block Flow Diagram (BFD)

BFD shows overall processing picture of a chemical

complex:

-Flow of raw materials and products may be included

on a BFD

-BFD is a superficial view of facility ChE information is

missing
 The Block Flow Diagram (BFD)

Example 1:
Mixed Gas
Toluene, C7H8 2610 kg/hr
10,000 kg/hr

Reactor Gas Separator Benzene, C6H6

C6H6
8,210 kg/hr
CH4
Hydrogen H2
820 kg/hr C7H8
Mixed Liquid

75% Conversion of
Toluene

Reaction : C7H8 + H2 C6H6 + CH4

Figure 1.1: Block Flow Diagram for the Production of Benzene

Example 2

Production of Ethane from Ethanol

Ethanol is feed to continuous reactor with presence of Acid Sulphuric
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 Ni
CH3CH3

Hot water out

Ethylene, CH2CH2 (g) Ethylene liq. CH2CH2 (l)

Ethanol,
Cold water in Ethane, CH3CH3
C2H5OH CH2CH2
Reactor 1 Reactor 2
H2SO4 H2O Hydrogen, H2
Distillation
column Ni

H2O
 The Block Flow Diagram (BFD)

Exercise 1:

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 where upper stream is insoluble NH 3 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.
 The Block Flow Diagram (BFD)

Answer 1

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
 The Block Flow Diagram (BFD)

Exercise 2:

Ethanol-water mixture is feed to a batch distillation column.

This distillation process will produce ethanol vapour at the top
product which then condensate to produce liquid ethanol which
then collected into a distillate product tank. This liquid ethanol
and an acetic acid liquid from a acid feed tank are then feed to
a reactor. An exothermic chemical reaction will producing ethyl
acetate (a type of ester). Draw BFD for this chemical process.
 The Block Flow Diagram (BFD)

Answer 2
Hot water
out

Ethanol
Condenser liq.
Ethyl
acetate
Reactor
Batch
distillation
Distillate
Cold product tank
water in
Ethanol-water
mixture

Acid feed
tank
The Process Flow Diagram (PFD)

PROCESS FLOW DIAGRAM

 The Process Flow Diagram (PFD)

SCOPE:

Students will be able to know:-

Process Unit symbology

How to read and draw PFD

Process equipments symbol and numbering

 The Process Flow Diagram (PFD)

Process Flow Diagram (PFD)

PFD shows all process engineering information:

-The topology of the process showing the connectivity of

all the streams and the equipment.

-Use appropriate conventions consistency is important in

communication of process information.
 The Process Flow Diagram (PFD)

PFD will contains the following information:-

- All major pieces of equipment (descriptive name,
unique equipment no.), pumps and valves.
- All the utility streams supplied to major equipments
such as steam lines, compressed air lines, electricity,
etc.
- All process flow streams: identification by a number,
process condition, chemical composition.
- Basic control loops: showing the control strategy used
to operate the process under normal operations.
The Process Flow Diagram (PFD)
 The Process Flow Diagram (PFD)

PFD will contains the following information:-

- All major pieces of equipment (descriptive
name, unique equipment no.), pumps and
valves.
- All the utility streams supplied to major
equipments such as steam lines, compressed
air lines, electricity, etc.
 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 A separator unit used

commonly to liquid mixture
into gas phase

Absorber A separator unit used

commonly to extract mixture
gas into liquid phase
 The Process Flow Diagram (PFD)

Process Unit Symbology

Symbol Name Description

Distillation A separator unit used

commonly to crack liquid
column contains miscellaneous
component fractions.

Liquid mixer A process unit that used to

or
mix several components of
liquid.
 The Process Flow Diagram (PFD)

Process Unit Symbology

Symbol Name Description

Reaction A process unit where

chemical process reaction
chamber occurs

Horizontal tank A unit to store liquid or gas.

or cylinder
 The Process Flow Diagram (PFD)

Process Unit Symbology

Symbol Name Description

Boiler A unit for heating.

Centrifuge A separator unit that to

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
Symbol Name

Relief Valve

Needle Valve

3-Way Valve

Angle Valve

Butterfly Valve
Example 3
Production of Ethane from Ethanol
Ethanol is feed to continuous reactor with presence of Acid Sulphuric
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 PFD for these processes.
H2SO4
CH3CH2OH CH2=CH2 + H2O
CH2=CH2 + H2 Ni
CH3CH3

R-100 P-100 T-100 E-100 P-101 R-101

Reactor Pump Distillation Column Condenser Pump Reactor

Hot water out

Ethylene Ethylene liq.

E-100

V-104
Cold water
in V-106
CV-100 T-100
CV-101
V-105
Ethanol
V-101 V-102
H2SO4 V-100 Hydrogen
V-103 V-107 Ni
R-100 Ethane
R-101
P-100
H2O
P-101
 The Process Flow Diagram (PFD)

Exercise 3:

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 where upper stream is insoluble NH 3 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
Process Flow Diagram (PFD) for this process.
 The Process Flow Diagram (PFD)

Answer 3
T-100 T-101 E-100
Absorber Column Batch Distillation Column Condenser

Insoluble ammonia
gas Hot water out

Ammonia gas
Ammonia liquid
Water 5 L/min
Cold water in

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

Process Unit Tagging and Numbering

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
 The Process Flow Diagram (PFD)

Y Letter

Area No. 1

Area No. 2

Area No. 3
 The Process Flow Diagram (PFD)

A/B Letter

Example
Hot water Hot water
out out
Ethylene Ethylene liq. Ethylene Ethylene liq.

Cold Cold
water in water in
Ethanol
H2SO4
Hydrogen Ethane Hydrogen Ethane
Ni Ni
H2O H2O

P-100 A/B P-100 A

P-100 B

In PFD In real plant, it means like above

 The Process Flow Diagram (PFD)

PFD will contains the following information:-

- All process flow streams: identification by a
number, process condition, chemical
composition.
 The Process Flow Diagram (PFD)

Stream Numbering and Drawing

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

- Horizontal lines are dominant.

Yes No No
 Example 4

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
T-100 CV-101 V-106
CV-100

V-105
Ethanol 5
1 V-101 V-102
H2SO4
4 Hydrogen
V-100 9
V-103 V-107 Ni
R-100
R-101 Ethane
3 8 10
2
H2O
7
P-101

P-100
The Process Flow Diagram (PFD) (cont..)

Stream Information

-Since diagrams are small not much stream information

can be included.

-Include important data around reactors and towers, etc.

Flags are used

Full stream data,

The Process Flow Diagram (PFD) (cont..)

Stream Information - Flag

600 Temperature
300
3 8 24 Pressure
9
6 7 10.3 Mass
1 10
Flowrate

108 Molar
600
Flowrate
24
2 5 12 Gas
Flowrate

11 Liquid
4
Flowrate
13
24
 Example 5

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
T-100 CV-101 V-106
25 CV-100
28
V-105
Ethanol 5
1 V-101 V-102 38 20
H2SO4
4 Hydrogen
V-100 9
V-103 V-107 Ni
R-100
R-101 Ethane
3 8 10
2 35
31.0 H2O
35 7
P-101
32.2
P-100
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)
 Example 6
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
V-106
25 T-100
CV-100 CV-101
28
V-105
Ethanol 5
1 20
V-101 V-102
H2SO4 4 38 Hydrogen
V-100 9
V-103 V-107 Ni
R-100
3 R-101 Ethane
2 8 10
35
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
 The Process Flow Diagram (PFD)

PFD will contains the following information:-

- Basic control loops: showing the control
strategy used to operate the process under
normal operations.
 Example 7
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 V-106
25 T-100
CV-100 CV-101
28
V-105
Ethanol 5 20
1 V-101 V-102
H2SO4 4 38 Hydrogen
V-100 9
V-103 V-107 Ni
R-100
3 R-101 Ethane
2 8 10
35
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
QUESTIONS?