Chap 4

FLOW SHEETING
This chapter covers the preparation and presentation of the process flow-sheet.
 The flow sheet is the key document in process design. It is a diagrammatic model
of the process.
 The flow sheet includes:
• Arrangement of the equipment selected to carry out the process
• The stream connections
• Stream flow-rates and compositions
• The operating conditions.
 Manual flow-sheeting calculations is tedious and time consuming when the
process is large or complex
 Hence, computer-aided flow-sheeting programs are used extensibly.
 Their use enables the designer to consider different processes and select the
best process and optimum process conditions
FLOW SHEETING
FLOW SHEET PRESENTATION
 Block diagrams:
• It is the simplest form of presentation.
• Each block can represent a single piece of equipment in a simple process
• Or principle stage in a complex process.
• Generally used in reports and textbooks, but have only a limited use as
engineering documents.
FLOW SHEETING
 Pictorial representation:
• On the detailed flow-sheets used for design and operation, the
equipment is normally drawn in a stylized pictorial form.
• Actual scale drawings of the equipment are sometimes used, but it is
more usual to use a simplified representation.
• Generally , British Standard, BS 1553 or American National Standards
Institute (ANSI) symbols are used.
• Appendix A lists some symbols.
FLOW SHEETING
 Pictorial representation:
FLOW SHEETING
PRESENTATION OF STREAM FLOW-RATES
 Simple method suitable for simple processes
• Tabulate the data in blocks alongside the process stream lines.
Data
blocks
• But only a limited amount of information can be shown in this way, and it
is difficult to make neat alterations or to add additional data.
FLOW SHEETING
 The other better method
• Each stream line is numbered and the data tabulated at the bottom of
the sheet. Figure 4.2
Stream
no.
FLOW SHEETING
 The other better method
• Each stream line is numbered and the data tabulated at the bottom of
the sheet. Figure 4.2
Stream Comp. & cond. of
no. the stream
FLOW SHEETING
 Information to be included:
• Stream composition,
• Total stream flow-rate.
• Stream temperature.
• Nominal operating pressure.
FLOW SHEETING
 Layout:
• The sequence of the main equipment items shown symbolically on the
flow-sheet follows that of the proposed plant layout.
• All the process stream lines shown on the flow-sheet should be
numbered and the data for the stream given.
• Complete, unambiguous information on all streams should be given,
even if this involves some repetition.
• Some license must be exercised in the placing of ancillary items, such as
heat exchangers and pumps, or the layout will be too congested.
• The equipment should be drawn approximately to scale.
• The stream line numbers should follow consecutively from left to right of
the layout, as far as is practicable for ease of location of the equipment.
• The continuation of the process streams from one sheet to another must
be clearly shown in a complex process involving many sheets.
FLOW SHEETING
 Layout:
• The continuation of the process streams from one sheet to another must be
clearly shown in a complex process involving many sheets. Example Fig. 4.2.
FLOW SHEETING
 Layout
• The components should be listed down the left-hand side of the table.
• For a long table it is good practice to repeat the list at the right-hand
side, so the components can be traced across from either side.
Components
FLOW SHEETING
 Basis of the calculation:

 It is good practice to show on the flow-sheet the basis used for the flow-
sheet calculations. This would include:
• Operating hours per year
• The reaction and physical yields
• The datum temperature used for energy balances
• Normally high precision on the process flow-sheet is not needed.
 Include a list of principal assumptions used in the calculations.
 Special limitation alerts

FLOW SHEETING
 Batch processes:
 Normally show the quantities required to produce one batch.
 If a batch process forms part of a continuous process, it can be shown on

the same flow-sheet.
 But a clear break should be made data between the continuous and
batch sections; For example the change from kg/h to kg/batch.
 A continuous process may include batch make-up of minor reagents,

such as the catalyst for a polymerization process.
FLOW SHEETING
 Equipment identification:
 Each piece of equipment shown on the flow-sheet must be identified
with a code number and name.
 For example: H ̶ heat exchangers, C ̶ columns, R ̶ reactors.
FLOW SHEETING
MANUAL FLOW SHEET CALCULATIONS
 External constraints: Not directly under the control of the designer, and which
cannot normally be relaxed.
• Product specifications, set by customer requirements.
• Major safety considerations, such as flammability limits.
• Effluent specifications, set by government agencies.
 Internal constraints: Determined by the nature of the process and the equipment
functions.
• The process stoichiometry, reactor conversions and yields.
• Chemical equilibria and Physical equilibria, involved in liquid-liquid and
gas/vapor-liquid separations.
• Azeotropes and other fixed compositions.
• Energy-balance constraints. Where the energy and material balance
interact, as for example in flash distillation.
• Any general limitations on equipment design.
FLOW SHEETING
 Scaling factor:
• It is usually easiest to carry out the sequence of flow-sheet calculations in the
same order as the process steps
• Start with the raw-material feeds and progressing stage by stage where
possible, through the process to the final product flow.
 Required production rate will usually be specified in terms of the product, not the
raw-material feed.
 Hence an arbitrary basis for the calculations, say 100 kmol/h of the principal raw
material is selected and multiplied.
𝑚𝑜𝑙𝑠 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑝𝑒𝑟 ℎ𝑜𝑢𝑟 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑒𝑑
 𝑆𝑐𝑎𝑙𝑖𝑛𝑔 𝑓𝑎𝑐𝑡𝑜𝑟 =
𝑚𝑜𝑙𝑠 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑝𝑟𝑜𝑑𝑢𝑐𝑒𝑑 𝑝𝑒𝑟 100 𝑘𝑚𝑜𝑙 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑟𝑖𝑛𝑐𝑖𝑝𝑎𝑙 𝑟𝑎𝑤 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙
FLOW SHEETING
 Flow sheet calculations on individual units: Some of the design constraints can
be used to determine stream flow and composition.
• Reactor
• Reactor yield and conversion specified
• Chemical equilibrium
• Equilibrium stage: The stream compositions can then be calculated from the
phase equilibrium data for the components.
• Fixed stream compositions
• Combined heat and material balances.
FLOW SHEETING
COMPUTER AIDED FLOW SHEETING
 Full simulation programs
• Require powerful computing facilities
• Capable of carrying out rigorous simultaneous heat and material
balances and preliminary equipment design.
• Produce accurate and detailed flow-sheets
 Simple material balance programs

• Require only a relatively small core size.
• These are an aid to manual calculations
• Enable preliminary flow-sheets to be produced quickly and cheaply.
FLOW SHEETING
FULL STEADY-STATE SIMULATION PROGRAMS
 Table 4.1
Aspen Plus
Dynamics for
dynamic processes.
FLOW SHEETING
 Sequential-modular programs
• Here the equations describing each process unit (module) are solved module-
by-module in a stepwise manner
• Iterative techniques used to solve the problems arising from the recycle
• Simulate the steady-state operation of the process
• Capable of carrying out rigorous simultaneous heat and material balances
and preliminary equipment design.
• Produce accurate and detailed flow-sheets.
 Equation based programs:
• Here the entire process is described by a set of differential equations, and the
equations solved simultaneously: not stepwise
• Equation based programs can simulate the unsteady-state operation of
processes and equipment.
FLOW SHEETING
Sequential Modular Approach Equation Oriented Approach
Simulate one unit model at Solve all unit models together

a time
Decompose flow sheet Order equations
Iterate in tear streams Update all unknown variables
simultaneously
Less flexible but more robust More flexible but less robust
Initialization is important Initialization is very important
Storage requirement not high Storage requirement can be
very high
FLOW SHEETING
 Sequential-modular programs
• Advantage: Less computing time
• Limitation: Obtain convergence to solve recycles problems. Unable to
simulate the dynamic, time dependent, behavior of a process.
 Equation based programs:

• Advantage: Able to model unsteady state conditions usually occurring at
start-up.
• Disadvantage: Require high computing power and time.
FLOW SHEETING
A typical simulation program Operator
Software
Controls and keeps track of

the flow-sheet calculations
and flow of information to &
from sub-routines
FLOW SHEETING
INFORMATION FLOW DIAGRAMS
FLOW SHEETING
INFORMATION FLOW DIAGRAMS
FLOW SHEETING
MANUAL CALCULATIONS WITH RECYCLE STREAMS
 The split-fraction concept

FLOW SHEETING

FLOW SHEETING

FLOW SHEETING

FLOW SHEETING

FLOW SHEETING
 Processes with reaction

FLOW SHEETING
 Processes with reaction (Example)

FLOW SHEETING

FLOW SHEETING

FLOW SHEETING

FLOW SHEETING
Guide rules for estimating split-fraction coefficients
 Reactor: %age conversion.
 Mixers
 Dividers
 Absorption or stripping columns
 Distillation columns
 Equilibrium separators

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FLOW SHEETING

 Basis of the calculation:

 Include a list of principal assumptions used in the calculations.

 Special limitation alerts

 If a batch process forms part of a continuous process, it can be shown on

 A continuous process may include batch make-up of minor reagents,

 Simple material balance programs

Simulate one unit model at Solve all unit models together

 Equation based programs:

Controls and keeps track of

 The split-fraction concept

 The split-fraction concept

 The split-fraction concept

 The split-fraction concept

 The split-fraction concept

 Processes with reaction

 Processes with reaction (Example)

 Processes with reaction (Example)

 Processes with reaction (Example)

 Processes with reaction (Example)

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