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

2. Course Information Instructor:
Dr. Mingheng Li Office: Phone:
Webpage:
Course Material:
Course Schedule:
MWF 10:00AM - 10:50AM (section 3)
Office Hours:
MWF 9:00-10:00 A.M.
Prerequisites:
ChE441/451L
Corequisite:
ChE452L

3. 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,
Coulson and Richardson, Chemical Engineering Design.
Yu, Process Design for Chemical Engineers (available from Amazon.com)
Perry, Chemical Engineers Handbook.

4. 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.

5. 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.

6. 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

7. 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 : %  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 R. Turton and J. A. Shaeiwitz

8. Tentative schedule:
Final Schedule
Tentative schedule

9. Process Design Courses
CHE design major equipment (pumps, compressors, heat exchanger, reactor, column, etc.) for unit operations.
CHE design two typical chemical processes (ammonia manufacturing process and the oil refining process).
CHE 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.

10. 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 R. Turton and J. A. Shaeiwitz

11. 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 R. Turton and J. A. Shaeiwitz

12. 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 R. Turton and J. A. Shaeiwitz

13. 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 R. Turton and J. A. Shaeiwitz

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

15. 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?

16. 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.

17. 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

18. 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

19. 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

20. Question: What do the flags mean?

21. 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

22. Question: explain the shown control loops

23. 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.

24. 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 R. Turton and J. A. Shaeiwitz

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

26. Questions: Explain the instruments in the circle

27. 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 R. Turton and J. A. Shaeiwitz

28. 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

29. 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

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

31. 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.