Equipment flow diagram

Mild steel is a satisfactory constmction material for all equipment in Ziegler chemistry processes except for hydrolysis. If sulfuric acid hydrolysis is employed, materials capable of withstanding sulfuric acid at 100°C are requited lead-lined steel, some alloys, and some plastics. Flow diagrams for the Vista and Ethyl processes are shown in Eigures 3 and 4, respectively. 

The first step in the procedure is to define the purpose, objectives, and scope of the study. The more precisely this is done, the more focused and relevant the committee discussions can be. The next step is to collect all relevant information on the process under consideration. This includes flow diagrams, process equipment specifications, nominal flows, etc. The procedure is highly dependent on the reflabiUty of this information. Efforts expended here are worthwhile. Many committees use the flow sheet as the central stmcture to organize thek discussions. 

The layout can only be started after a process flow diagram is available. The process flow diagram includes information such as the principal equipment items and order of the process flow. A sized equipment Hst is also useful from the standpoint of knowing what spaces are required to fit the equipment. Availabihty of a preliminary piping and instmmentation drawing (P ID) provides more information to aid in spacing equipment and thinking about piperack requirements. 

Fig. 3. Process flow diagram for a continuous falling film SO sulfonation plant, equipped with a sulfur-burning SO converter unit. See text.

Electrochemical processes require feedstock preparation for the electrolytic cells. Additionally, the electrolysis product usually requires further processing. This often involves additional equipment, as is demonstrated by the flow diagram shown in Figure 1 for a membrane chlor-alkali cell process (see Alkali AND chlorine products). Only the electrolytic cells and components ate discussed herein. 

Air-Based Direct Oxidation Process. A schematic flow diagram of the air-based ethylene oxide process is shown in Figure 2. Pubhshed information on the detailed evolution of commercial ethylene oxide processes is very scanty, and Figure 2 does not necessarily correspond to the actual equipment or process employed in any modem ethylene oxide plant. Precise information regarding process technology is proprietary. However, Figure 2 does illustrate all the saUent concepts involved in the manufacturing process. The process can be conveniently divided into three primary sections reaction system, oxide recovery, and oxide purification. 

Base equipment includes all equipment within the battery limits whose cost is as significant as the cost of a pump. For example, storage tanks, knockout drums, accumulators, heat exchangers, and pumps are classed as main-plant items (MPl). Early in the development of the process-flow diagram, it is advisable to increase the estimated (MPl) cost by 10 to 20 percent to allow for later additions. When the scope of the process has been well defined, (MPl) costs should be increased by 1 to 10 percent. 

The use of process flow diagrams and material balances are worthwhile methods to quantify losses or emissions and provide essential data to estimate the size and cost of additional equipment, other data to evaluate economic performance, and a basefine for tracking the progress of minimization efforts (Ref. 3). Material balances should be apphed to individual waste streams or processes and then utilized to construct an overall balance for the facility. Details on these calculations are available in the literature (Ref. 8). In addition, an introduction to this subject is provided in the next section. 

Process Flow Diagram (PFD) A diagram that shows the material flow from one piece of equipment to the other in a process. It usually provides information about the pressure, temperature, composition, and flow rate of the various streams, heat duties of exchangers, and other such information pertaining to understanding and conceptualizing the process. 

Block flow diagram A simplified drawing representing a process. It typically shows major equipment and piping and can include major valves. 

Once the candidate corrective measure alternatives have been identified, a more detailed evaluation of each alternative needs to be undertaken. From an engineering perspective, the first step in the evaluation process would include the development of a conceptual design for each alternative. The conceptual design would consist of a process description, a process flow diagram and a layout drawing. Preliminary sizing of equipment and utility and land requirements would be developed. In addition, chemical requirements and residuals produced can be estimated. From the conceptual design, permitability and residuals disposal issues can be identified and addressed. 

If the control valve size is critical to the overpressure protection of the downstream equipment, and must not be increased, then this is clearly noted in all relevant documentation (specification sheets, flow diagram, operating manual, etc.,) and a warning notice plate is welded to the valve body. In such cases, an actual check of the valve installed or purchased should be made during the startup review. 

A block flow diagram is used to show the major process equipment and interconnecting process flow lines and flow rates, stream composition, temperatures, and pressures when necessary for clarity. The block flow diagram is a simplified diagram. 

The process flow diagram, or PP D. is a pictorial description of the process. It gives the basic processing scheme, the basic control concept, and the process information from which equipment can be specified and designed. It pror ides the basis for the der elopment of the P l diagram and also serves as a guide for the plant operator. The process flow diagram usiuilly includes... 

Prepare/supervise preparation of piping or mechanical flow diagram (or P and ID), with necessary preliminary sizing of all pipe lines, distillation equipment, pumps, compressors, etc., and representation of all instrumentation for detailing by instrument engineers. 

Figure 1-5A. Pictorial sections flow diagram for principal operations phosphate recovery. By permission, Deco Trefoil, 1958, Denver Equipment Co.

---