Module 3 BFD,PFD and P&ID for Chemical Processes

Objectives
To define different streams in a process To describe the meaning of standard abbreviations and symbols used on process flowsheets Write a description of a process flowsheet Draw a process flowsheet from a written description
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Introduction
A process is some operation carried out to modify input(s) to output(s) based on physical and/or chemical changes
Inputs feeds Process Outputs products

Role of a Chemical Engineer Specification of equipment and materials and their subsequent arrangement into processes The analysis of the operation in order to alter the processing operation to achieve a desired result Both problems require analysis and design functions
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Cont
Example: Problem in an oil fired boiler in an oil refinery Solution: Analyze problem If problem due to air supply then correct it by suggesting modifications For this we have suggest design for a new air blower
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Ways of Describing Processes

Input output diagram Block flow diagram (BFD) Process Flow Diagram (PFD) Process and Instrumentation Diagram (P&ID)
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Block Flow Diagram (BFD)

Raw Materials Process

Products

Block Flow Diagram

Group of connected blocks of process units Lines with arrows connect blocks and represent process streams Raw materials enter on the left Products exit on the right 4 kinds of process units:
Mixers Reactors Splitters Separators
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butter C12H22O11 flour eggs NaCl NaHCO3 Chocolate chips Mixer Raw chocolate chip Cookie dough

Raw chocolate chip Cookie dough

Reactor (Oven)

Baked chocolate chip Cookies

4 dozen cookies 75% choc chip 25% peanut butter Splitter

3 dozen cookies 75% choc chip 25% peanut butter

1 dozen cookies 75% choc chip 25% peanut butter

4 dozen cookies 75% choc chip 25% peanut butter Separator

3 dozen cookies 97.5% choc chip 2.8% peanut butter

1 dozen cookies 8.3% choc chip 91.7% peanut butter

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Classification of Processes
An integrated series of operations through which materials and/or energy are converted from one form to another Batch process e.g. fine chemicals Continuous process e.g. distillation Semi batch or Semi continuous e.g. fermentation
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Example:
1. A coffee maker 2. An oil refinery 3. A toaster 4. The kidney 5. An alcohol production unit
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Process Flow Diagram

A PFD or process flow diagram shows the basics without the inner workings of equipment or the control schemes. The concept of the flowsheet is applicable to many industries The essential elements are
The different operations that make up the process The sequence in which these operations occur (i.e. the relationship between the operations)
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Example: A home oil burner

Flue gas to chimney

Cool air from house

Warm air to house

oil

Air

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Flue gas to chimney Cool air

Warm air to house

Fan/blower

oil
Storage tank

Air

pump

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Flue gas to chimney

house

Cool air

Warm air to house

Fan/blower

oil
Storage tank

Air

pump

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How to draw a PFD

Draw a flowsheet from the following simplified description of the synthesis of ammonia: A mixture of hydrogen and nitrogen is fed to a catalytic reactor where some of the hydrogen and nitrogen is converted to ammonia. The reactor effluent is sent to a condenser where all of the ammonia is condensed. The condensed ammonia is sent to product storage. The uncondensed hydrogen and nitrogen are recycled by being mixed with a fresh feed of the same composition. The resulting mixture is fed to the reactor.
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Type of process?
Reactor and condenser are continuous Storage tank is semi-continuous

Reaction: N2 + 3H2

2NH3

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A mixture of hydrogen and nitrogen is fed to a catalytic reactor where some of the hydrogen and nitrogen is converted to ammonia. The reactor effluent is sent to a condenser where all of the ammonia is condensed. The condensed ammonia is sent to product storage. The uncondensed hydrogen and nitrogen are recycled by being mixed with a fresh feed of the same composition. The resulting mixture is fed to the reactor.
Step 1 is the feed to the reactor:

feed N2 H2

reactor

effluent NH3 N2 H2

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A mixture of hydrogen and nitrogen is fed to a catalytic reactor where some of the hydrogen and nitrogen is converted to ammonia. The reactor effluent is sent to a condenser where all of the ammonia is condensed. The condensed ammonia is sent to product storage. The uncondensed hydrogen and nitrogen are recycled by being mixed with a fresh feed of the same composition. The resulting mixture is fed to the reactor.
Step 2 is to purify the product:

feed N2 H2

reactor

condenser effluent NH3 N2 H2 NH3 liquid

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A mixture of hydrogen and nitrogen is fed to a catalytic reactor where some of the hydrogen and nitrogen is converted to ammonia. The reactor effluent is sent to a condenser where all of the ammonia is condensed. The condensed ammonia is sent to product storage. The uncondensed hydrogen and nitrogen are recycled by being mixed with a fresh feed of the same composition. The resulting mixture is fed to the reactor.
Step 3 is to send product to storage:

feed N2 H2

reactor

condenser effluent NH3 N2 H2 NH3 liquid Storage tank

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A mixture of hydrogen and nitrogen is fed to a catalytic reactor where some of the hydrogen and nitrogen is converted to ammonia. The reactor effluent is sent to a condenser where all of the ammonia is condensed. The condensed ammonia is sent to product storage. The uncondensed hydrogen and nitrogen are recycled by being mixed with a fresh feed of the same composition. The resulting mixture is fed to the reactor.
Step 4 is to recycle unreacted feeds: recycle purge N2, H2 feed N2 H2

reactor

condenser effluent NH3 N2 H2 NH3 liquid Storage tank

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Piping and Instrumentation Diagram (P&ID)

Plant construction information (piping, process, instrumentation, and other diagrams)

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Instrumentation and Control

Instruments are used to sense process variables and drive control valves. These are denoted on P&IDs by circles with letters:
LC FRC

Valves are connected by solid lines to the point where variables are measured, and by dotted lines to the equipment they control
FRC

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Instrumentation symbols
As 1st letter
A C F I L P R T V D r flow Level/liquid Pressure Temperature Differential ratio indicator level Recorder Differential ratio Valve analyzer -

As 2nd letter
Alarm controller -

As 3rd letter
Alarm controller -

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Cont
First letter describes the variable sensed by the instrument: Pressure (P), Temperature (T), Flow (F), level or liquid level (L or LL), composition (A) The second and third letters describe the action taken: Record ( R), Indicate (I), Sound an alarm (A), or Control (C ) Explain the symbols:
LC FRC

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Description
Main pieces of equipment are the column (C1), accumulator drum (D1), reboiler (E2) and condenser (E1). The distillation column (C1) separates the feed stream according to volatility into overhead and bottoms products. The heat exchangers (E1) and (E2) condense the overhead vapors and partially vaporize the liquid from the bottom of the column. The drum (D1) accumulates the condensed liquid and also accommodates surges in overhead product rate. Control elements are shown by circles and dashed lines.

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Control Elements
The rate of bottoms withdrawal is controlled by the liquid level in the bottom of the column. When the level rises the valve is opened to increase the withdrawal rate and thus lower the level. The net bottoms flow is controlled by an analyzer (with recorder) which sets the flow controller on the steam to the reboiler to maintain the bottoms composition within specified limits. The net overhead is withdrawn from the drum on level control (i.e. when the level in D1 rises the valve is opened). This keeps the level in the tank within a preset upper and lower limits.
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Cont
The rate at which reflux is returned to the column is controlled by the Temperature at a particular point in the column, when this temperature rises the valve is opened and more reflux flows to the column. This instrument is an indicator as well as a controller so it sends a signal proportional to the temperature to a readout instrument in the control room. The column is feed controlled by an FRC.

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