What disciplines are involved in the design of a process package?
The development of a process package is a systematic project. It involves a number of disciplines and specialisms and is difficult to complete on your own. Generally speaking, process package development and design is a joint effort between R&D, chemical process, process systems, analysis and laboratory, automation, materials, safety and health, environmental protection and other disciplines to complete the process package design for the chemical product.
What design documents should be included in the finished process package?
The finished process package should include instructions, a process flow diagram (PFD), a preliminary piping and instrumentation flow diagram (P&ID), a proposed equipment layout, a list of process equipment, a process equipment data sheet (with equipment sketches), a summary of catalysts and chemicals, a summary of sampling points, a materials manual (if required), a safety manual (including occupational health, safety and environmental protection), an operations manual (including an analysis manual ), physical data manuals and relevant calculations.
The quality control of the process package design is the same as the quality control requirements for the basic/preliminary design phase for all relevant disciplines as defined in the company's design standards.
Detailed specification of the content and depth of the process package design
1 Specification The process package design specification is an important part of the process package design and should include the following
a) Production methods, plant characteristics; depicting the advancedness, reliability and plant characteristics of the process production methods used in the process package design.
b) Name and size of product, annual operating hours, and mode of operation of the plant, operating in five shifts of three or four shifts of three, or other modes.
c) List the names of the sections that make up the plant in the order of the process.
d) List the names of the equipment and equipment that produce the three wastes, as well as the name, quantity, composition and form of discharge of the three wastes, and a description of the comprehensive use and treatment of the three wastes.
(1) Design basis
List the names and specifications of the relevant raw materials, catalysts and chemicals respectively.
List the names and specifications of water, electricity, gas, steam and other public works respectively.
(2) Process design
Describe the principles of the process, list the chemical reaction equations involved in the process (including primary and secondary reactions) and describe the catalysts used.
Detailed description of the process flow by section and system (tower system,
Reactor system, compressor system) in accordance with the sequence of the process.
List the normal operating conditions at each major point, such as temperature, pressure, flow rate, composition and main control indicators, by section and system (tower system, reactor system, compressor system).
List expected and guaranteed values for product specifications, product yields and raw material consumption.
List the main utility consumption indicators.
Detailed description of process control principles by section and system (tower system, reactor system, compressor system) and a description of the process safety interlock system.
The selection of key equipment such as reactors, main mass transfer equipment, main heat exchange equipment and pumps is described in terms of structure, form and material selection.
2 Drawings Process flow diagram (PFD) with material balance sheet.
Piping and instrumentation flow diagram (P&ID).
A proposed equipment layout drawing.
The proposed equipment layout drawing should include the following: suggested and indicative dimensions of the form of the building or structure, relative position and relative elevation between equipment (expressed to scale, no need to indicate specific dimensions), relative position or elevation or height difference of equipment with special requirements (specific dimensions must be indicated), names and bit numbers of all or major equipment, relative position of control rooms and main operating rooms.
3 Tables List of process equipment; data sheet of process equipment (with sketch of equipment); summary table of catalysts and chemicals; summary table of sampling points (where required)
4 Safety manual (including occupational health, safety and environmental protection) Briefly describe the main contents of the safety manual, the purpose of its preparation and its role. Process description.
Includes a description of the chemical principles and the process flow of the plant. Detailed data on the basic physical and chemical properties of raw materials, intermediate and final products and on fire, explosion and toxicity and their means of control. Measures taken to prevent accidents such as fires, explosions and poisoning and the means of control for the nature of the plant. For example, provisions for ventilation, emergency exits, fire extinguishers, safety showers, eyewash, respiratory equipment, and the provision of personal protective equipment.
5 Operating manuals A brief introduction to the main contents of the operating manual, the purpose of its preparation and its role.
Description of chemical principles, plant processes and utility systems, with reduced PFD and P&ID diagrams.
A list of the recommended operating parameters for the sections or systems (reactor systems, tower systems, compressor systems, etc.) and the impact of changing these operating parameters on the plant
Mainly for equipment, piping machinery for the final inspection steps, proposed valve and related equipment machinery lubrication steps, equipment and piping cleaning and purging steps, instrumentation inspection and calibration steps, pumps, compressors and other equipment commissioning and operation steps requirements.
Start-up steps, normal operation steps, normal stopping and accident stopping steps
Detailed normal and accidental stopping procedures for process units and utility auxiliary units.
6 Analysis manual A brief description of the main contents of the analysis manual, the purpose of its preparation and its role, and the responsibilities, organisation and collaboration of the analysis department.
The basic requirements for the design of sampling points are briefly explained and the specific location, type of sampling point, analysis items and frequency of analysis for each sampling point in the entire installation are listed in the form of a summary table of sampling points.
Sampling procedures include the following: safety precautions for sampling operations, preparation of sampling containers, sampling procedures and sample preparation and handling, techniques and methods for obtaining representative samples.
A list of analytical methods used for sampling and analysis throughout the plant, including those for raw materials and products, as well as relevant analytical methods for each section of the plant and system.
Process package development for chemical processes
The chemical production process consists of two main components: reaction and separation. The reaction process is the core of chemical production and the separation process is an important means of ensuring the purity of the product.
The task of the reaction process is to determine the reaction route and to optimise the parameters to obtain the optimum reaction conditions. The following factors need to be taken into account when choosing the route and conditions: yield, conversion, selectivity, energy consumption, safety, stability, corrosiveness of the medium (involving the choice of materials) the amount of three wastes to be treated, investment in equipment, operating costs, etc.
The common separations in chemical plants are gas-liquid separation, absorption, gas extraction, analysis, distillation, etc. The applicable working conditions of different separation means are different. Trade-offs should be made in relation to the material composition and separation requirements.
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