Introduction to Chemical Process Industries
Presented by:
Engr. Waqas Ahmed Khan
Chemical Engineering Department
University of Wah
Process
Movement of data or material towards a known goal or end result,
by passing it through a series of stages or a sequence of actions.
Depratment of Chemical Engineering 2
Sections of A Chemical Plant
• Process
• Utility
• Safety
• Maintenance
• Ware House
• Research and Development
• Quality and Control
Laboratories
• Administration
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Course Outline
• Fundamentals of Chemical Process
• Introduction to process flow sheeting
• Detailed study of the following group of industries:
– Drinking water treatment
– Acid industries
• Hydrochloric acid
• Sulphuric acid
• Nitric acid
• Phosphoric acid
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– Alkali industries – Miscellaneous Chemical
• Soda ash • Explosives industry
• Caustic soda • Insecticides industry
• Ammonia • Surface coating industry
– Fertilizer industries (NPK based – Refinery and Petrochemicals
fertilizers) – Food and food by-products
– Silicate industries – Industrial gases (Oxygen and
• Cement industry Nitrogen)
• Glass industry
• Ceramics industry
– Agro-based industries
• Pulp and Paper industry
• Soap and Detergent
• Oil and Ghee industry
• Sugar industry 5
Recommended/Reference Books
• Shreve’s Chemical Process Industries by George T. Austin ,5th Or 6th Edition
• Handbook of Industrial Chemistry and Biotechnology by James A. Kent, 12th
Edition, 2012
• Chemical Process Technology by J. Moulijn, M. Makkee, and A. van Diepen, 2nd
Edition, 2013
• Introduction To Chemical Processes (Principles, Analysis And
Synthesis), International Edition, Regina M. Murphy
• A Text Book Of Chemical Technology, G. N. Pandey, Volume I
• Chemical Engineering, D. Kuznetsov
• Hawley's Condensed Chemical Dictionary
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Course learning outcomes
• CLO-I: Identify standard symbols for process equipment and
interpret process flow diagrams
• CLO-II: Explain the process flow diagram, feedstock and
product requirements and process conditions for important chemical
industries
Fundamentals of chemical process
• Basic chemical data
– Chemistry/Kinetics
– Material/energy changes and balances
– Batch versus continuous processing
• Chemical process selection, design and operation
– Pilot plants
– Equipment
– Material of construction
• Chemical process economics
• Market evaluation
• Safety
• Research and development 8
Terminologies in chemical process
• State • Reaction
– States of matter – Physical
– Steady state – Chemical
– Uniform state • Separation/Purification
• Phase • Heat Exchange
• Temperature
• Pressure
• Heat
• Flow
• Equipment/Apparatus/Instruments
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Chemical Process Diagrams
• The most effective way of communicating information about a process
is through the use of flow diagrams.
• Flow Diagrams
– Block Flow Diagrams (BFD)
– Process Flow Diagrams (PFD)
– Piping and Instrument Diagrams (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.
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
• Emphasis is not on the details regarding blocks and focus is on the flow
of streams through process.
• Conventions:
– Operations shown by blocks
– Major flow lines shown with arrows giving flow direction
– Flow goes from left to right whenever possible
– Light streams toward top, heavy streams toward bottom
– Critical information unique to the process supplied (i.e., reaction stoichiometry, conversion)
– Avoid crossing lines; horizontal continuous, vertical broken.
– Simplified material balance (overall)
Block Flow Diagram (BFD)
Block Flow Plant Diagram
Process Flow Diagram (PFD)
• PFD shows all process engineering information
• Typical conventions (vary by company):
– All major equipment represented, uniquely numbered
– All process flow streams shown and uniquely numbered, with description of
thermodynamic conditions and composition (often in an
accompanying table)
– All utility streams supplied to major process equipment shown
– Basic control loops, illustrating control strategy during normal operation
Process Flow Diagram (cont’d)
Process Flow Diagram (cont’d)
Process Flow Diagram (cont’d)
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
D
ensity
Piping & Instrument Diagram
• Piping & Instrument Diagram (P&ID) – Construction Bible
• Contains plant construction information (piping, process, instrumentation)
• Support documents of the PFD used for planning for plant construction
and maintaining the plant thereafter
• Each PFD requires many P&IDs to provide the necessary data
• Used as a checklist at the final walk-through prior to start up to assure each detail has
been attended to
• Use by/to
– MEs and CEs to build/install equipment
– Instrument engineers to specify/install/check control systems
– Piping engineers to develop plant layout and elevation drawings
– Project engineers to develop plant and construction schedules
Piping & Instrument Diagram
Stream Numbering & Drawing
• Number streams left to right when possible
• Horizontal lines are dominant
yes no no
Stream Information - Flags
Stream Drawing
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