Process Plant Engineering PDF

CHAPTER 1 Process Plant Engineering -- is a specialized branch of engineering focused on designing, implementing industrial process for manufacturing plants. - It ss a multidisciplinary field focused on designing, implementing ad managing complex systems used in industrial manufacturing and...

CHAPTER 1 Process Plant Engineering -- is a specialized branch of engineering focused on designing, implementing industrial process for manufacturing plants. - It ss a multidisciplinary field focused on designing, implementing ad managing complex systems used in industrial manufacturing and processing. OVERVIEW OF PPE - Core objectives - Process design development - Project management - Safety and Environmental consideration - Control and automation - Optimization and improvement - Maintenance and troubleshooting - Quality assurance - Training and support - Innovation and research WHAT INVOLVES: 1. Process Design -- Developing the overall layout and design of the process systems. 2. Equipment Specification -- Choosing and specifying the equipment needed for the process. 3. Safety and compliance -- Ensuring that process is designed to meet the standard and regulatory requirements. 4. Optimization -- Improving existing process to increase efficiency. 5. Project management -- It includes coordinating with contractors and managing budgets. 6. Maintenance and Troubleshooting -- Developing maintenance plans and troubleshooting issues arise in plant to ensure continuous and efficient operation. 7. Integration and control -- Implementing control systems and automation monitor ensuring optimal performance. IMPORANTANCE OF PPE -- It is critically important for several reason as it plays a central role in the efficiency, safety and economically viable which contribute to the overall success of industrial operations. - Efficiency and productivity - Cost reduction - Safety - Regulatory compliance - Quality control - Environmental impact - Innovation and Competitive edge - Reliability and maintenance - Scalability - Economic impact ROLES OF PPE -- are diverse and encompass a wide range of responsibilities essential for the successful operation and management of industrial processes. ENGINEERING DISCIPLINES -- Designing and managing process plants involves a combination of multiple engineering disciplines. Each disciplines contributes a specific expertise to ensure that the plant operates efficiently safely and effectively. 1. Chemical Engineering- Focus on chemical process involved 2. Mechanical Engineering -- Involved in the design and specification of mechanical system and equipment 3. Electrical Engineering -- handles electrical systems and control systems within the plant 4. Instrumentation and Control Engineering -- Focus on measurement and control process variables 5. Civil Engineering -- Address the structural and infrastructural aspects of plants 6. Environmental Engineering -- Ensures that the plant meets the environmental regulations and minimize impact 7. Industrial Engineering -- Focuses on optimizing process efficiency and operations 8. Safety Engineering -- Ensure that the plant operates safely and meets safety regulation 9. Systems Engineering -- Managing the integration of various engineering systems and components. 10. Project Management -- Planning and execution of plant design project 11. Materials Engineering -- Focuses on selecting and testing materials used in plant construction and operation CHAPTER 2 INSTRUMENTATION -- It is composed of variety of devices and systems used to measure, monitor and control physical quantities in industrial processes. 1. Pressure Transducers -- Measure the pressure of gas 2. Temperature Sensors- Measure temperature 3. Flow meter -- measure the flow rate of liquid or gas 4. Level sensor -- detect the level of liquid or fluid in a container 5. pH meter -- measure the acidity or alkalinity of a solution 6. Gas Analyzer -- measure the concentration of gas in mixture 7. Strain gauges -- Measure the amount of deformation or strain in a material 8. Data loggers -- Record data from various sensors over time 9. Flow controllers -- regulate the flow rate of liquid or gas 10. Vibration sensors -- Monitor vibrations in machinery to detect imbalances or potential failures. MECHANICAL EQUIPMENT AND SYMBOLS a. Pumps -- It is essential for moving fluids from one location to another b. Compressors -- used to increase the pressure of gases by reducing their volume c. Heat exchangers -- it is used to transfer heat between two or more fluids without them mixing (HOW? EXPLAIN) d. Fans -- they are mostly used in ventilation e. Blowers -- it is designed to move or displaces the air the fan made f. Heat recovery system -- it is design to capture and reuse waste from various process g. Storage tank and vessel -- It is used for holding and storing fluids gas and other materials h. Filters -- used to remove contaminants or particles from fluids to improve quality i. Separators -- it is designed to separate different components such as density, size or chemical affinity j. Mixers -- use to blend combine or stir materials to achieve a certain mixture k. Agitators - use to blend combine or stir materials to achieve a certain mixture l. Motor -- It provide the power and control needed to drive machinery and equipment m. Drives -- Control the speed and torque of an AC motor n. Conveyers -- used to transport goods materials within industrial settings and they help streamline operation o. Elevator- used to elevate equipment p. Boiler -- used to generate steam and they operate by heating water or other fluids to produce steam or hot water. ELECTRICAL EQUIPMENT TYPES AND SYMBOLS -- they are essential for understanding electrical diagrams and schematics. - Power supply equipment Transformer -- steps up or down voltage Battery -- Provides DC voltage Generator -- Converts mechanical energy to electrical energy - Switch and relays Single Pole Single Throw (SPST) switch -- simple on and off switch Single Pole Double Throw (SPDT) switch -- switch that routes a signal to one of two outputs - Protective Device Fuse -- protects circuits by breaking the connection when current exceeds Circuit breaker -- automatically interrupts the circuit to protect against overload - Load devices Lamp -- Converts electrical energy to light Motor -- Converts electrical energy to mechanical Resistor -- Limits current flow in a circuit - Measuring instruments Voltmeter -- measure voltage Ammeter -- measure current Ohmmeter -- measure resistance - Ground -- reference point in electrical circuit from which voltages are measured VALVE TYPES Gate valve -- used to start or stop the flow of fluid; not typically used for regulating flow Globe valve -- used for throttling flow making it suitable for regulating flow Ball valve -- provides quick on/off control with minimal pressure drop; not ideal for throttling Butterfly valve -- used for isolating flow especially in large-diameter pipes Check valve -- prevents back flow, ensuring one way flow system Diaphragm valve -- ideal for controlling flow of corrosive, abrasive or dirty fluids Relief Valve -- automatically releases pressure to protect system from overpressure Needle valve -- provides precise flow control particular in low-flow applications Solenoid valve- Electrically controlled valve used for automatic fluid control CHAPTER 3 PETROCHEMICALS -- are non-fuel compounds derived from crude oil and natural gas and has the ability to create diverse range of polymers. - There are 10% bio ethanol on a gas station Base chemicals can be classified in 2 groups Olefin -- have chain of carbon atoms as their backbone Aromatics -- contains ring of carbon atom at the core of molecule The 2 cracking methods used in olefin plant cracker are thermal cracking (high temp) and cat cracking (using catalyst) Figure 6. (Explain) page 85 Ethylene -- petrochemical industry's key building block. THE MAJOR PLASTIC OR POLYMERS Polymerization -- is the linking of individual molecules or monomers such as ethylene into long chains of polymers such as polyethylene. Bulk/gas phase polymerization -- Most common production methods and is used in the manufacture of polyethylene and polypropylene Solution polymerization -- the monomer is dissolved in a solvent and resultant polymer is also soluble Slurry polymerization -- the polymer is produced as slurry or paste from solvent-based system Suspension polymerization -- this process is used when both the monomer and polymer are insoluble in the solvent but catalyst is soluble. Emulsion polymerization -- this high-cost method used in manufacture of special later polymers PETROCHEMICAL PROCESSES -- they are important in producing wide range of products essential in modern life including fuels, chemicals plastics and fertilizers. 1. Crude oil distillation -- the first step in refining crude oil where crude oil is heated and separated into different components base on their boiling points. 2. Steam cracking -- process where hydrocarbon (typically naphtha or ethane) is subjected to high temperature in the presence of steam 3. Catalytic cracking -- a process that uses catalyst to breakdown larger hydrocarbon 4. Hydrocracking -- process that combines hydrogen with heavy hydrocarbon in the presence of catalyst to produce lighter products 5. Reforming -- process where naphtha is converted into higher octane gasoline 6. Alkylation -- process that combines smaller molecules with larger molecules to produce high octane gasoline 7. Isomerization -- process that rearranges the structure of hydrocarbon to improve their properties 8. Aromatics production -- process such as reforming and extraction are used to produce aromatic hydrocarbons 9. Olefin production -- processes like steam cracking are used to produce olefins 10. Polymerization -- process of converting monomers into polymers through chemical reaction Polyethylene (PE) -- used in packaging, containers and films Polypropylene (PP) -- used in automotive parts, textiles and packaging Polyvinyl Chloride (PVC) -- Used in pipes, flooring and electrical insulation 11. Methanol production -- methanol is produced from natural gas through steam reforming and methanol synthesis 12. Urea production -- urea is produced from ammonia and CO2 though Haber-Bosch process 1. Crude oil- complex mixture of hydrocarbons extracted from earth 2. Natural Gas -- mixture of hydrocarbon primarily methane extracted from underground reservoir 3. Naphtha -- light distillate fraction from crude oil 4. Ethane -- byproduct of natural gas processing 5. Propane -- hydrocarbon gas extracted from natural gas processing 6. Butane -- Gas separated from natural gas 7. Aromatics -- derived from catalytic reforming of naphtha 8. Methanol -- produced from natural gas through steam reforming 9. Ammonia -- Produce from natural gas using Haber-Bosch process 10. Coal -- can be used to produce syngas which then converted into chemicals like methanol/ammonia 11. Syngas -- mixture of hydrogen and carbon monoxide produce from natural gas 12. Renewable feedstocks -- example bioethanol biodiesel and biogas KEY CONSIDERATION IN RAW MATERIAL SELECTION - Availability - Cost - Quality - Environmental impact - Sustainability