Chemical Plants - Stages

Feasibility study

Basic Design
Detail Design
Construction
Commissioning
Normal operation

Optimization
1

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feasibility

4/19/2015

Basic design
BFD

Distillation

4/19/2015

Basic design
Reaction

4/19/2015

Basic design
Gas Separator

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Basic design
Distillation Section

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Basic design
Toluene

Benzene

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Basic design

REACTO
R
TULUEN
E

BENZENE

4/19/2015

Detail design
Process Topology
Equipment List
stream Information
Philosophy & Equipment Control (P&ID)

4/19/2015

Detail design

Anatomy
Of
Chemical Process

10

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Detail design
Separation Reaction
Equipment Equipment

11

Heat
Transfer
Equipment

Fluid
Transfer
Equipment

Storage Control Process

Equipment
Equipment

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Detail design

Equipment Information
Unit/
Tag No

12

Type/
Model

Service
Description

Power/
Duty/
Driver type

Efficiency/
Mass Flow/
Conversion/
Phase
Capacity

P-T
Design/
Operation

P/T/F Pressure
In-Out
Drop

Height /
Orientation/
Length/
Material/
Diameter/
Insulation
Area

Number of try/
Reflux ratio

4/19/2015

Detail design
Stream List Information
Stream Number
Temperature
Pressure
Vapor Fraction
Total Mass Flow rate
Total Mole Flow rate

Density
Viscosity
Heat Capacity
Stream Enthalpy
K- Values
Material & Energy
(balance)

13

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Detail design
line list
Stream Number

Temperature (C)
Pressure (bar)
Vapor Fraction
Mass Flow
(tonne/h)
Mole Flow
(kmol/h)

10

59

25

225

41

600

41

38

654

90

1.90

25.8

25.5

25.2

25.5

25.0

25.5

23.9

24.0

2.6

0.0

0.0

1.00

1.0

1.0

1.0

1.0

1.0

1.0

0.0

10.0

13.3

0.82

20.5

6.41

20.5

0.36

9.2

20.9

11.6

108.7

144.2

301.0

1204.4

758.8

1204.4

42.6

1100.8 1247.0

142.2

0.0

0.0

286.0

735.4

449.4

735.4

25.2

651.9

652.6

0.02

0.0

0.0

15.0

317.3

302.2

317.3

16.95

438.3

442.3

0.88

0.0

1.0

0.0

7.6

6.6

7.6

0.37

9.55

116.0

106.3

108.7

143.2

0.0

144.0

0.7

144.0

0.04

1.05

36.0

35.0

25

Component Mole
Flow (kmol/h)
Hydrogen
Methane
Benzene
Toluene
14

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Detail design

Equipment Information
Unit/
Tag No

15

Type/
Model

Service
Description

Power/
Duty/
Driver type

Efficiency/
Mass Flow/
Conversion/
Phase
Capacity

P-T
Design/
Operation

P/T/F Pressure
In-Out
Drop

Height /
Orientation/
Length/
Material/
Diameter/
Insulation
Area

Number of try/
Reflux ratio

4/19/2015

Detail design

Valve list
Item

16

Valve
Type

Fluid
Properties

Pressure Class/CV/
Rating/Size

Flanges/Fitting/
Pipes/End/
Bolt-Gasket

Material
Actuator
Body

Trim

4/19/2015

Detail design
Heat equipment Sizing
Separation equipment Sizing
Fluid equipment Sizing
Reaction equipment Sizing

17

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Detail design

Control Loop

18

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Detail design

Control Loop Symbols

19

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Detail design

20

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Detail design

21

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Detail design

Control Loop

22

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Detail design

Instrument Location

23

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Detail design

24

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Detail design

25

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Detail design

26

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Detail design
Project:

Node:

Page:
Date:
Drw No

Node description: Distillation Column

Guideword

Cause

Consequence

Safeguard

Record

Recommendation

High pressure

Water failure in
condenser

Condenser vent will

act as relief device

Pressure indicator
on column, high
pressure alarm +
Action on FCV

High level

Level controller
fault

Flooding of tower

High Level Alarm

independent of
level controller

Low level

Level controller
mail function or
low flow

Not a problem

Project:

Node:

27

Cause

Reverse flow

Cooling of
condenser &
T101 after
shutdown

High pressure

Water failure
low

Action

HAZOP
MINUTE
SHEET

High Level Alarm

independent

Page:
Date:
Drw No

Node description: condenser

Guideword

INDIV

Consequence
Suck back of air
into T101 on
cooling

Excess pressure

Safeguard

Record

Recommendation

Consider Nitrogen
purge

Back up cooling water

system /
Thermocouple on vent
(TAH)

INDIV

Action

4/19/2015

Detail design

28

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Detail design

29

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Detail design

Instrument & Control equipment list

30

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PFD
Toluene

31

Benzene

4/19/2015

P&ID

Detail design
Simulation

33

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Construction

34

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Optimization

35

4/19/2015