Process design

In chemical engineering, process design is the choice and sequencing of units for desired physical and/or chemical transformation of materials. Process design is central to chemical engineering, and it can be considered to be the summit of that field, bringing together all of the field's components. Process design can be the design of new facilities or it can be the modification or expansion of existing facilities. The design starts at a conceptual level and ultimately ends in the form of fabrication and construction plans. Process design is distinct from equipment design, which is closer in spirit to the design of unit operations. Processes often include many unit operations. Process design documents serve to define the design and they ensure that the design components fit together. They are useful in communicating ideas and plans to other engineers involved with the design, to external regulatory agencies, to equipment vendors and to construction contractors. In order of increasing detail, process design documents include: Block flow diagrams (BFD): Very simple diagrams composed of rectangles and lines indicating major material or energy flows. Process flow diagrams (PFD): Typically more complex diagrams of major unit operations as well as flow lines. They usually include a material balance, and sometimes an energy balance, showing typical or design flowrates, stream compositions, and stream and equipment pressures and temperatures. Piping and instrumentation diagrams (P&ID): Diagrams showing each and every pipeline with piping class (carbon steel or stainless steel) and pipe size (diameter). They also show valving along with instrument locations and process control schemes. Specifications: Written design requirements of all major equipment items. Process designers typically write operating manuals on how to start-up, operate and shut-down the process. They often also develop accident plans and projections of process operation on the environment. Documents are maintained after construction of the process facility for the operating personnel to refer to.