Lecture 2

Process design development

 Process design development

1. TYPES OF DESIGNS:

The methods for carrying out a design project may

be divided into the following classifications,
depending on the accuracy and detail required:

1. Preliminary or quick-estimate designs.

2. Detailed-estimate designs.
3. Firm process designs or detailed designs.
 1. Preliminary designs
2. Detailed-estimate design:
are ordinarily used as a basis for
In this type of design, the cost
determining whether further
and profit potential of an
work should be done on the
established process is determined
proposed process. The design is
by detailed analyses and
based on approximate process
calculations. However, exact
methods, and rough cost
specifications are not given for
estimates are prepared. Few
the equipment, and drafting-room
details are included, and the
work is minimized.
time spent on calculations is
kept at a minimum.
Important factors to be considered before entering in
Detailed-estimate design:
1. Manufacturing process
2. Material and energy balances
3. Temperature and pressure ranges
4. Raw material and product specification
5. Yield, reaction rate and time cycle
6. Material of construction
7. Utilities (Steam , water and fuel)
8. Plant site (Plant location)
 3. Firm process design:

is the final step before developing

construction plans for the plant. It is
characterized with complete
specifications for all components of
the plant, accurate costs based on
quoted prices are obtained,
blueprints and sufficient information
to permit immediate development of
the final plans for constructing the
plant, and complete flow sheet is
presented.
 2. Feasibility Survey

Before any detailed work is done on the design, the technical

and economic factors of the proposed process should be
examined.

The various reactions and physical processes involved must

be considered, along with the existing and potential market
conditions for the particular product.

A preliminary survey of this type gives an indication of the

probable success of the project and also shows what
additional information is necessary to make a complete
evaluation.
Following is a list of items that should be considered in making a feasibility
survey:

1. Raw materials (availability, quantity, quality, cost)

2.Thermodynamics and kinetics of chemical reactions involved (equilibrium,
yields, rates, optimum conditions)
3. Facilities and equipment available at present
4. Facilities and equipment which must be purchased
5. Estimation of production costs and total investment
6. Profits (probable and optimum, per pound of product and per year, return on
investment)
7. Materials of construction.
8. Safety considerations.
9. Markets (present and future supply and demand, present uses, new uses,
present buying habits, price range for products and by-products, character,
location, and number of possible customers)
10. Competition (overall production statistics, comparison of various
manufacturing processes, product specifications of competitors)
11. Properties of products (chemical and physical properties,
specifications, impurities, effects of storage).
12. Sales and sales service (method of selling and distributing, advertising
required, technical services required).
13. Shipping restrictions and containers.
14. Plant location.
15. Patent situation and legal restrictions.
 3. Flow diagrams

The chemical engineer uses flow diagrams to show the sequence of

equipment and unit operations in the overall process, to simplify
visualization of the manufacturing procedures, and to indicate the
quantities of materials and energy transfer. These diagrams may be
divided into three general types: (1) qualitative, (2) quantitative,
and (3) combined-detail.

A qualitative flow diagram indicates the flow of materials, unit

operations involved, equipment necessary, and special information
on operating temperatures and pressures. A quantitative flow
diagram shows the quantities of materials required for the process
operation. An example of a qualitative flow diagram is shown in
the following figure:
[Qualitative process flow diagram for the manufacture of nitric acid by the
ammonia-oxidation process].
An example of a quantitative flow diagram is shown in the following figure:

[Quantitative process flow diagram for the manufacture of nitric acid by the ammonia-
oxidation process].
An example of a combined flow diagram is shown in the following figure:

[Combined process flow diagram for the manufacture of nitric acid by the
ammonia-oxidation process].
 4. The Flow Sheet Importance

 Shows the arrangement of the equipment selected to carry

out the process.
 Shows the streams concentrations, flow rates &
compositions.
 Shows the operating conditions.
 During plant start up and subsequent operation, the flow
sheet from a basis for comparison of operating performance
with design. It's also used by operating personnel for the
preparation of operating manual and operator training.
 5. Type of Flow Sheet

1. Block Diagram
2. Pictorial Representation
3. Presentation of stream flowrates
4. Information be included
5. Layout
6. Precision of data
7. Basis of calculation
8. Batch Processes
9. Services (Utillities)
10. Equipment
11. Computer aided diagram
1- Block diagram
 Represent the process in a simplified form.
 No details involved.
 Don’t describe how a given step will be achieved.

When is it used?
 In survey studies.
 Process proposal for packaged steps.
 Talk out a processing idea.
2- Pictorial Flow Sheet:
The equipments are normally drawn in a stylized pictorial form. For
tender documents or company brochures actual scale drawing of the
equipment are sometimes used.
 6. Types of pictorial Flow Sheets

a) Process Flow Diagram (PFD):

A PFD is a simplified flow diagram of a single process unit, a utility unit, a
complete process module.

The purpose of a PFD is to provide a preliminary understanding of the process

system indicating only the main items of equipment, the main pipelines and the
essential instruments, switches and control valves.

 A PFD also indicates operating variables, such as mass flow, temperatures and
pressures, which are tabulated at various points in the system.
The PFD is a document containing information on:
 Process conditions and physical data of the main process
streams.
 Main process equipment with design data.
 Main Process lines.
 Mass (material) balance.
 Heat balance (if applicable).

NOTE: If the PFD doesn’t contain any data about the flow rates, it
is called a qualitative flowsheet, while if the flow rates are involved
the PFD is called a combined flowsheet in which qualitative
information and quantitative data are combined on the basis of one
flowsheet.
Qualitative process flow diagram (PFD) for the manufacture of nitric acid
by the ammonia-oxidation process.
b) Piping and Instrumentation Diagram (P & ID)
(mechanical flow diagram):
A P&ID diagram shows the arrangement of the process
equipment, piping, pumps, instruments, valves and other
fittings. It should include:

 All process equipment identified by an equipment number.

 All pipes identified by a line size, material code and line
number.
 All valves with an identified size and number.
 Fittings.
 All pumps identified by a suitable code number.
 All control loops and instruments.
Process and Instrument Diagram (P&ID)
 c) Utility Flowsheet (Process Engineering Utility Flow Diagram
(PEUFD)):

 Used to summarize and detail the interrelationship of utilities such as air,

water (various types), steam (various types), heat transfer mediums, process
vents and purges, safety relief blow-down, etc., to the basic process. The
amount of detail is often too great to combine on other sheets, so separate
sheets are prepared.
 The PEUFD is a document containing information on:
 Main distribution or arrangement of each individual utility system, expect
electrical systems.

PEUFD Function:
The PEUFD shall state characteristics and consumption figures of the
particular utility concerned, cooling water, fire water, drinking water,
steam, plant air, instrument air, fuel oil/gas, inert gas and similar
utilities.
d) Process Safeguarding Flow Diagram (PSFD):
The PSFD is a document highlighting information on:

Types and levels of protection offered by the devices

installed and their inter relation to demonstrate the
plant’s safety.
The P&ID contains all information required for a
PSFD; however, the PSFD highlights protection in
case of extreme conditions and measures to be taken
to safeguard personnel and environment.