PROCESS FLOW DIAGRAM (PFD)

WITH

MASS AND ENERGY BALANCE

By
J. D. Singh

PROCESS & TECHNOLOGY-GROUP

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1.0 Definition of a PFD
Before discussing about PFD, following fundamental concept about mass and
energy balance should be considered.
• Mass can neither be created nor destroyed.
• Energy gets transformed from one form to another but does not get
destroyed.
Any process particularly a chemical process can be presented by a block
diagram. The fundamental of developing a PFD is input mass or energy into a
system will be equal to output plus accumulation/rejection from the system.

2.0 Concept of Balance

2.1 Mass
Sum total of mass of Component in stream A will be equal to sum total of mass
of component in stream B along with P-(drain) and V- Vent. Fig-1 shows mass
balance of process/ system.
Mass of stream A = Mass of stream (B+P +V)
m1 = m2 + m3 +m4
Stream V (Vent), m3

PROCESS SYSTEM
Stream A , m1 Stream B, m2

Stream P( Purge), m4

Fig -1

2.2 Energy
Total Energy E in stream A will be equal to sum total of energy of stream B, P
and V. Fig-2 shows energy balance of process/ system.

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 Energy of stream A = Energy of stream (B+P +V)
E1 = E2 + E3 +E4

Stream V (Vent), E3

Stream A, E1 Stream B, E2
PROCESS SYSTEM

Stream P ( Purge), E4

Fig 2

The basis of mass and energy balance for a PFD :

• Sum of mass of all input streams to a system is equal to sum of mass of all
streams leaving the same system.
• Sum of energies of all entering stream to a system is equal to sum of all
energies of outgoing stream from the same system.

2.3 Example
For further clarity and understanding a simple process of raising of steam from a
boiler is considered :
Water is introduced to boiler at a given flow rate to generate and supply steam
from it. Fig 3 & 4 depicts overall mass and energy balance for the boiler.
Mass balance is considered for water and steam circuit only, there is no mass
exchange from fuel (gas) circuit with water circuit.
The water entering the system with mass m1 generates m2 amount of steam
with m3 amount lost in purge and m4 through vent.

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 Fig. 3 Mass Balance

Overall Mass Balance

Inlet flow of water to boiler drum m1 mass / time.
Outlet flow of steam from boiler m2
Purge stream m3
Leakage loss m4
m1 = m2 + m3 +m4
Mass of stream 1 = Mass of stream (2 + 3+4)

Energy balance is made for inlet stream and outlet streams to and from the
system. This includes both water as well as fuel & flue gas circuit.

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 Fig .4 Energy Balance
Overall Heat balance
Heat in with water-stream 1 h1 (unit of heat).
Heat out with steam-stream 2 h2
Heat out with purge-stream 3 h3
Heat out with leakage-stream 4 h4
Heat in with fuel-stream 5 h5
Heat out with flue gas-stream 6 h6
Within the system,
Heat in with stream (1 + 5) = heat out with stream( 2+ 3+4+5+6)
h1+h5 = h2+h3+h4+h6

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3.0 Initiator of PFD
3.1 An engineer of Chemical/ Mechanical Discipline initiate the concept/ flow
diagram. Flow diagram can be for any one of the following.

3.2 Utility System

• Water System
• Compressed Air System.
• Steam Generation and Distribution.
• Material Handling

3.3 Chemical Process/ System

• Distillation Continuous / Batch-system
• Reactor
• Any complex chemical processing system
• Storage and handling of Chemicals

4.0 Information needed to generate a PFD/ available from a PFD.

a) Process sequence description with flow diagram.
b) Equipment system used.
c) Stand-by equipment / system.
d) Connecting main flow lines/drain/vents.
e) Recirculation and Bypass Lines.
f) Flow rate of stream mass/ volumetric.
g) Temperature- 0 C/ K / 0
F.
h) Pressure- psi / kgcm2 (g)/atm
i) Composition of each stream… mole/mass/wt%.
j) Physical properties- (relevant)
• Specific gravity
• Molecular weight
• Specific heat
• Density
k) Major Control System.
l) Heat in / out to/from stream / equipment.

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 m) Stream Number
n) Equipment tag number/ equipment list
o) Any special feature of scheme.

5.0 Use of PFD

PFD helps is developing/ preparing engineering documents and generation of
following information/data.
a) Data sheets of equipments.
b) Process data sheets for instrument items
c) P&ID.
d) In finalising scheme of Layout.
e) Choice of MOC.
f) Properties/characteristics of stream and its composition.
g) Finalisation of equipment and instrument list.

6.0 Conclusion

PFD forms basis of all engineering/design documents of chemical /Industrial projects /

plants.

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