CHEMICAL PROCESS INDUSTRY
LECTURE 1
Chemical Process Diagrams
Outline
Flow Diagrams
Block Flow Diagrams (BFD)
Process Flow Diagrams (PFD)
Piping and Instrument Diagrams (P&ID)
Other common diagrams
3-D plant layout diagrams
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 1
3 Levels of Diagram
Block Flow Diagram (BFD)
Process Flow Diagram (PFD)
Piping and Instrumentation Diagram (P&ID) –
often referred to as Mechanical Flow Diagram
Complexity Conceptual
increases understanding
increases
As chemical engineers, we are most familiar
with BFD and PFD.
The 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
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 2
Definitions of BFD
Block Flow Process Diagram
Figure 1.1
Similar to sketches in material and
energy balances
Block Flow Plant Diagram
Figure 1.2
Gives a general view of a large complex
plant
The Block Flow Process Diagram
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 3
Developing a Process
Target product is 37% formaldehyde in water. Known as
formalin
Occurs of a silver catalyst at 200 oC and 2 – 3 atm
pressure
Reaction 1 is the predominant reaction
Develop a block flow diagram that describes the process
B.P. Pure formaldehyde = -19.3 oC
B.P. Formalin = 96 oC
R. Turton and J. A. Shaeiwitz -
Copyright 2008
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 4
The Block Flow Plant Diagram
R. Turton and J. A. Shaeiwitz -
Copyright 2008
The Process Flow Diagram
PFD shows all process engineering
information
Diagram developed in junior year design
projects (especially the 2nd semester)
Often PFD is drawn on large paper –
textbook breaks down information into 1
diagram and 2 tables
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 5
The Process Flow Diagram (cont’d)
The topology of the process – showing the
connectivity of all the streams and the
equipment
Example for toluene HDA – Figures 1.3 and
1.5
Tables 1.2 and 1.4 – list information that
should be on the PFD but cannot fit
Use appropriate conventions – consistency is
important in communication of process
information
ex. Table 1.2
The Process Flow Diagram (cont’d)
R. Turton and J. A. Shaeiwitz -
Copyright 2008
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 6
The Process Flow Diagram (cont’d)
Table 1.2 : Conventions Used for Identifying Process Equipment
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 Additional description of equipment given on top of PFD
Information
R. Turton and J. A. Shaeiwitz -
Copyright 2008
Equipment Numbering
XX-YZZ A/B/…
XX represents a 1- or 2-letter designation
for the equipment (P = pump)
Y is the 1 or 2 digit unit number (1-99)
ZZ designates the equipment number for
the unit (1-99)
A/B/… represents the presence of spare
equipment
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 7
R. Turton and J. A. Shaeiwitz -
Copyright 2008
Equipment Numbering (cont’d)
Thus, T-905 is the 5th tower in unit nine
hundred P-301 A/B is the 1st Pump in unit
three hundred plus a spare
Use unambiguous letters for new equipment
Ex. 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
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 8
Stream Numbering and
Drawing
Number streams from left to right as
much as possible
Horizontal lines are dominant
yes no no
R. Turton and J. A. Shaeiwitz -
Copyright 2008
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 9
Stream Numbering and
Drawing (cont’d)
Add arrows for
Change in direction
Inlet of equipment
Utility streams should use convention
given in Table 1.3, lps, cw, fg, etc.
Stream Information
Since diagrams are small, not much
stream information can be included
Include important data – around
reactors and towers, etc.
Flags are used – see toluene HDA
diagram
Full stream data, as indicated in Table
1.4, are included in a separate flow
summary table – see Table 1.5
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 10
R. Turton and J. A. Shaeiwitz -
Copyright 2008
Stream Information - Flags
R. Turton and J. A. Shaeiwitz -
Copyright 2008
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 11
The Process Flow Diagram (cont’d)
Table 1.4: Information in a Flow Summary
Essential Information
Stream Number
Temperature (°C)
Pressure (bar)
Vapor Fraction
Total Mass Flow Rate (kg/h)
Total Mole Flow Rate (kmol/h)
Individual Component Flow Rates (kmol/h)
Optional Information
Component Mole Fractions
Component Mass Fractions
Individual Component Flow Rates (kg/h)
Volumetric Flow Rates (m3/h)
Significant Physical Properties
Density
Viscosity
Other
Thermodynamic Data
Heat Capacity
Stream Enthalpy
K-values
Stream Name
R. Turton and J. A. Shaeiwitz -
Copyright 2008
The Process Flow Diagram (cont’d)
A Portion of Table 1.5
Stream Number 1 2 3 4 5 6 7 8 9 10
Temperature (°C) 25 59 25 225 41 600 41 38 654 90
Pressure (bar) 1.90 25.8 25.5 25.2 25.5 25.0 25.5 23.9 24.0 2.6
Vapor Fraction 0.0 0.0 1.00 1.0 1.0 1.0 1.0 1.0 1.0 0.0
Mass Flow (tonne/h) 10.0 13.3 0.82 20.5 6.41 20.5 0.36 9.2 20.9 11.6
Mole Flow (kmol/h) 108.7 144.2 301.0 1204.4 758.8 1204.4 42.6 1100.8 1247.0 142.2
Component Mole Flow
(kmol/h)
Hydrogen 0.0 0.0 286.0 735.4 449.4 735.4 25.2 651.9 652.6 0.02
Methane 0.0 0.0 15.0 317.3 302.2 317.3 16.95 438.3 442.3 0.88
Benzene 0.0 1.0 0.0 7.6 6.6 7.6 0.37 9.55 116.0 106.3
Toluene 108.7 143.2 0.0 144.0 0.7 144.0 0.04 1.05 36.0 35.0
R. Turton and J. A. Shaeiwitz -
Copyright 2008
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 12
Basic Control Loops
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
Basic Control Loops
R. Turton and J. A. Shaeiwitz -
Copyright 2008
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 13
Equipment Information
Equipment are identified by number
and a label (name) positioned above
the equipment on the PFD
Basic data such as size and key data
are included in a separate table
(Equipment Summary Table) Table 1.7
(and Table 1.6) in TBWS
Equipment Information
A Section of Table 1.7: Equipment Summary
Vessel V-101 V-102
Temperature (ºC) 55 38
Pressure (bar) 2.0 24
Orientation Horizontal Vertical
MOC CS CS
Size
Height/Length 5.9 3.5
(m)
Diameter (m) 1.9 1.1
Internals s.p. (splash plate)
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 14
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 (Chapter 5) and cost of
manufacture (Chapter 6) to be made.
The Piping and Instrument
Diagram(P&ID)
P&ID – Construction Bible
Contains: plant construction information
(piping, process, instrumentation, and
other diagrams)
P&ID information is explained in Tables
1.8 and 1.9
Conventions for instrumentation are
shown in Figure 1.10
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 15
P&ID
R. Turton and J. A. Shaeiwitz -
Copyright 2008
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
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 16
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
Other Common Diagrams
Section of Plot Plan Section of Elevation Diagram
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 17
Other Common Diagrams (cont’d)
Piping Isometrics – show piping in 3-
dimensions
Vessel Sketches – show key dimensions
of equipment and locations of inlet and
outlet nozzles etc.
Scale Models and Virtual Plants
25 years ago physical models were used for
review
Now virtual or electronic models are
generated using software (3-d plant
diagrams)
Purpose of Models – catch errors such as
Piping clashes
Misaligned piping
Equipment not easily accessed
Sample points not easily reached by operators
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 18
3-D Plant
Diagrams
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.
Copyright 2003 - R. Turton and J. A.
Shaeiwitz 19
