Lecture 1: Syllabus, BFD, PFD, and P&IDs CHE442 Chemical Processes Synthesis and Design II

Course Information Instructor: Dr. Mingheng Li Office: 17-2102 Phone: 909-869-3668 Email: minghengli@cpp.edu Webpage: http://www.cpp.edu/~minghengli/che442.html Course Material:http://www.cpp.edu/~minghengli/che442 Course Schedule: MWF 10:00AM - 10:50AM (section 3) Office Hours: MWF 9:00-10:00 A.M. Prerequisites: ChE441/451L Corequisite: ChE452L

Texts and References Texts(Required): References: Turton et al, Analysis, Synthesis, and Design of Chemical Processes (4th Edition), Prentice Hall. Lecture notes by Dr. Nguyen References: Peters, Timmerhaus and West, Plant Design and Economics for Chemical Engineers, 5th Edition, McGraw Hill, 2003. Towler and Sinnott, Chemical Engineering Design, Butterworth-Heinemann, 2nd Edition, 2012. Seider, Seader, Lewin, Product and Process Design Principles: Synthesis, Analysis, and Evaluation, 2nd Edition, Wiley, 2008. Coulson and Richardson, Chemical Engineering Design. Yu, Process Design for Chemical Engineers (available from Amazon.com) Perry, Chemical Engineers Handbook.

Course Overview In CHE 442, the students will focus on and learn in detail two selected processes. The two processes chosen are the ammonia manufacturing process and the oil refining process. The ammonia process is a good candidate for the students to gain their first design experience, because it involves simple, familiar and well-defined components yet it is comprised of many important unit operations common to all chemical industries. As the operating temperature changes significantly throughout the process, it provides an excellent example for the students to learn and appreciate energy optimization through the design of a tightly-integrated heat exchanger network. The oil refining process is important to the students, because it represents a major industry in California. Many of our graduates and current students are working in the oil industry. From the technology standpoint, the refining process offers the students a totally different perspective than the ammonia process. Unlike many processes, which have one or two products, the refinery produces many products which have to satisfy many quality specifications. In this class, the students will also learn basic engineering economics including cost estimating and optimization techniques.

Course Objective The objective of this course is to give the students a working knowledge of design principles as applied in chemical engineering processes and operations. In this course, the students will learn how unit operations fit together and interact in these processes and the basic procedure in process engineering design. As the last stage of plant design, the student will learn the economics of process design. In addition to learning the techniques of plant design, students will also have an opportunity to discuss and address contemporary, social, economic and technological issues facing chemical engineers. Students will use Pro/II and/or HYSYS to perform simulations of industrial equipment and processes. Students will also learn basic concepts of optimization in design of chemical processes.

Course Outcomes The students will have Ability to synthesize a process plant using the onion diagram concept Ability to produce PFD and material and energy balances of a process Ability to cost-estimate a process plant Ability to assess profitability of a process plant Ability to assess alternate investment plans Ability to assess contemporary issues Ability to optimize process design using computational tools Ability to plan a design project Ability to manage a design project

Grading The student's course grade is determined by the total number of points he/she earns during the quarter. Make-up quiz will not be given; a missed quiz may be made-up only if absence is due to a legitimate reason approved by the instructor and substantiated by written verification. Homework 10% Contemporary Issues Quiz 60% Design Project Progress* 20% Total 100% No late homework. No make-up exams.  * Design project progress is measured by the quality of progress reports and the actual progress of the design project made during the last three weeks of the quarter. Design project description and definition will be provided at an appropriate time.  A : 93-100%  A- : 90-93%  B+ : 87-90%  B : 83-87%  B- : 80-83%  C+ : 77-80%  C : 73-77%  C- : 70-73%  D+ : 67-70%  D : 60-67%  F : 0-60% Copyright 2003 - R. Turton and J. A. Shaeiwitz

Tentative schedule: Final Schedule Tentative schedule

Process Design Courses CHE441 -- design major equipment (pumps, compressors, heat exchanger, reactor, column, etc.) for unit operations. CHE442 -- design two typical chemical processes (ammonia manufacturing process and the oil refining process). CHE443 -- Team project to perform process design and cost estimating of a complete plant with attention to environmental constraints. Since process design is very comprehensive, the design course is divided into three quarters. This quarter CHE441 focuses on major equipment design. Just like we first learn how to design each brick. Then using the bricks to build up two buildings in CHE442. The third quarter CHE443 is for team project. Let you build your own building.

Chemical Process Diagrams Flow Diagrams Block Flow Diagrams (BFD) Process Flow Diagrams (PFD) Piping and Instrument Diagrams (P&ID) Other common diagrams 3-D plant layout diagrams Complexity Conceptual increases understanding increases As chemical engineers, we are most familiar with BFD and PFD. Copyright 2003 - R. Turton and J. A. Shaeiwitz

Block Flow Diagram (BFD) BFD consists of a series of blocks representing different equipment or unit operations that were connected by input and output streams. Some important flowrates, T, P, conversion, yield, compositions No details of equipment Block Flow Process Diagram: for a single process with simple mass balance and key process function blocks. Copyright 2003 - R. Turton and J. A. Shaeiwitz

Block Flow Diagram (BFD) Block Flow Plant Diagram: a general view of a large complex plant Block Flow Plant Diagram: for multiple processes with flow connectivities. Copyright 2003 - R. Turton and J. A. Shaeiwitz

Process Flow Diagram – Topology PFD shows the connectivity of all the streams and the equipment with ChE information The location of and interaction between equipment and process streams are referred to as the process topology no universally accepted standards unique equipment number and a descriptive name. Streams number, process conditions and chemical composition on PFD or separate table. Utilities Control loop Copyright 2003 - R. Turton and J. A. Shaeiwitz

Process Flow Diagram – Equipment Information Equipment Symbol Equipment numbering Copyright 2003 - R. Turton and J. A. Shaeiwitz

Process Flow Diagram – Equipment Information Turbine use Tb or J not T (used for tower) Replace old vessel V-302 with a new one of different design - use V-319 (e.g.) not V-302 – since it may be confused with original V-302 Example: what does P-302 A/B means?

Process Flow Diagram – Equipment Information Equipment Summary (attached to PFD) Provides the information necessary to estimate the costs of equipment and furnish the basis for the detailed design of equipment.

Questions What’s the typical information required in equipment summary of a heat exchanger? Type, duty and/or area, T, P, material of shell and tube side What’s the typical information required in equipment summary of a vessel? T, P, Diameter, length, orientation, material, internals What’s the typical information required in equipment summary of a pump? Type, power, material, fluid, T, P, driven type

Process Flow Diagram – Stream Information Number streams from left to right as much as possible Add arrows for Change in direction Inlet of equipment Utility type: LPS, MPS, HPS, CW, hot oil, flue gas, fuel oil, etc. Horizontal lines are dominant yes no no

Process Flow Diagram – Stream Information Include important data – around reactors and towers, etc. Flags are used on diagram Full stream data are included in a separate flow summary table

Question: What do the flags mean?

Basic Control Loops (Optional) Often the basic control loops (those involving maintaining material balance and reactor controls) are included on the PFD; instrumentation and other control loops are not shown

Question: explain the shown control loops

PFD Summary PFD, Equipment Summary Table, and Flow Summary Table represent a “true” PFD This information is sufficient for a preliminary estimation of capital investment and cost of manufacture to be made.

Piping and Instrument Diagram(P&ID) Provides information needed by engineers to begin planning for the construction of the plant. No T, P, Flow information compared to PFD Spare units e.g. pumps Pipe size, thickness, material, insulation Instruments Valves Bypass lines Utilities Copyright 2003 - R. Turton and J. A. Shaeiwitz

P&ID Instruments Copyright 2003 - R. Turton and J. A. Shaeiwitz

Questions: Explain the instruments in the circle

Questions: Explain the instruments in the circle A level sensing element (LE) is located on the drum V-102. A level transmitter (LT) is also located on V-102 sends an electrical signal (designated by a dashed line) to a level console (as indicated the horizontal line under LIC) and can be observed by the operators. From the LIC, an electrical signal is sent to an instrument (LY) that computes the control valve position and in turn sends a pneumatic single (designated by a solid line with cross hatching) to activate the control valve (LCV). In order to warn operators of potential problems, two alarms are placed in the control room. There are a high-level alarm (LAH) and a low-level alarm (LAL), and they receive the same single from the level transmitter. Copyright 2003 - R. Turton and J. A. Shaeiwitz

Look at V-102 on P&ID V-102 contains an LE (Level Element) LE senses liquid level in separator and adjusts flow rate leaving LE opens and closes a valve depending on liquid level LE and valve represent a feedback control loop

Section of Elevation Diagram Other Common Diagrams Plot Plans – plan or map drawn looking down on plant (drawn to scale with all major equipment identified) Elevation Diagrams – show view from side and give information about equipments distance from ground Section of Plot Plan Section of Elevation Diagram

Other Common Diagrams (cont’d) Piping Isometrics – show piping in 3- dimensions General Arrangement / Top assembly – for equipment manufacturing Copyright 2003 - R. Turton and J. A. Shaeiwitz

Summary The three principal diagrams (BFD, PFD, and P&ID) are used to convey increasingly specific technical information about a process. Important to adhere to common standards for these diagrams in order to avoid confusion Information on equipment layout is most clearly conveyed through a 3-D plant layout diagram.