I often hear the “process package” mentioned by chemical workers.
What exactly does it include? The chemical process package (complete technology package) is the core of chemical production and plays a pivotal role in the chemical production process. So, what exactly does the chemical process package include?
What majors are required to complete the process package design?
Process package development is a systematic project. It needs to involve multiple majors and different disciplines, and it is difficult to complete it by yourself. Generally speaking, the process package development and design is mainly completed by the R&D, chemical process, process system, analysis and testing, automatic control, materials, safety and sanitation, environmental protection and other majors to complete the process package design of the chemical product.
What design files should be included in the finished craft package?
The finished product of the process package shall include instructions, process flow diagram (PFD), initial pipeline and instrumentation flow diagram (P&ID), suggested equipment layout, process equipment list, process equipment data sheet (equipment diagram attached), catalyst and chemical summary Table, summary table of sampling points, material manual (when necessary), safety manual (including occupational health, safety and environmental protection), operation manual (including analysis manual), physical property data manual and related calculation books.
The quality control of process package design is the same as the quality control requirements of each relevant specialty in the basic design/preliminary design stage stipulated in the company’s design standards.
Detailed regulations on the content and depth of process package design
The technical package design manual is an important part of the technical package design and should include the following contents:
a) Production method and device characteristics; describe the advancement, reliability and device characteristics of the process production method used in the process package design.
b) The name and scale of the product, the annual operating time, and the operation mode of the device, whether it is operated in three shifts in five shifts or three in four shifts, or in other ways.
c) According to the sequence of the process, list the names of each section of the device.
d) List the name of the equipment that produces the three wastes, the name, quantity, composition and discharge form of the three wastes, and the description of the comprehensive utilization and treatment of the three wastes.
(1) Design basis
The names and specifications of relevant raw materials, catalysts and chemicals are listed respectively.
List the names and specifications of water, electricity, gas, steam and other public works respectively.
(2) Process design
Describe the principle of the process, list the chemical reaction equations involved in the process (including main and side reactions), and explain the catalysts used.
According to the sequence of the process, the division of labor and the system (tower system, reactor system, compressor system) describe the process flow in detail.
Sections and systems (tower system, reactor system, compressor system) list the normal operating conditions of each main point, such as temperature, pressure, flow, composition and main control indicators.
List the expected and guaranteed values of product specifications, product output and raw material consumption.
List the main utility consumption indicators.
Sections and systems (tower system, reactor system, compressor system) describe the process control principle in detail, and explain the process safety interlock system.
The selection of key equipment such as reactor, main mass transfer equipment, main heat exchange equipment and pump is explained from the aspects of structure, form and material selection.
Process flow diagram (PFD), with material balance sheet attached;
Piping and Instrumentation Diagram (P&ID);
Proposed equipment layout;
The suggested equipment layout should include the following contents: suggestions on building and structure forms and reference dimensions, relative positions and relative elevations between equipment (expressed in proportion, no need to mark specific dimensions), relative positions of equipment with special requirements Or elevation or height difference (the specific size must be marked), the name and number of all or major equipment, and the relative positions of the control room and the main operating room.
List of process equipment; process equipment data sheet (equipment diagram attached); summary table of catalysts and chemicals; summary table of sampling points (when necessary)
4 safety manual (including occupational health, safety and environmental protection)
Briefly introduce the main content, purpose and function of the safety manual. Process Description:
Include chemical principles and a description of the process flow of the device. Basic physical and chemical properties of raw materials, intermediate products, and final products, as well as detailed data on fire, explosion, toxicity, etc., and their control methods. Measures and control measures taken to prevent fire, explosion, poisoning and other accidents according to the nature of the device. Such as ventilation, emergency exits, fire extinguishers, safety showers, eye wash stations, respiratory equipment, personal protective equipment and other regulations.
5 Operation Manual
Briefly introduce the main content, purpose and function of the operation manual.
Description of chemical principles, plant process flow, and utility systems, with miniature PFD and P&ID drawings attached.
List the recommended operating parameters of the section or system (reactor system, tower system, compressor system, etc.) and the impact of changing these operating parameters on the device
Mainly for the steps of final inspection of equipment and pipeline machinery, the steps of lubricating valves and related equipment and machinery, the steps of cleaning and purging of equipment and pipelines, the steps of instrument inspection and calibration, the steps of debugging and operation of pumps, compressors and other equipment Require.
Start-up steps, normal operation steps, normal stop and accident stop steps
Detailed normal shutdown and emergency shutdown procedures for process units and utility auxiliary installations.
6 Analysis Manual
Briefly introduce the main content of the analysis manual, the purpose of compilation and its function, as well as the responsibilities, organization and collaboration of the analysis department.
Briefly explain the basic requirements for sampling point design, and list the specific location, type of sampling point, analysis items and analysis frequency of each sampling point in the entire device in the form of a summary table of sampling points.
Sampling procedures include the following related content: safety protection measures for sampling operations, preparation of sampling containers, sampling procedures and sample preparation and handling, techniques and methods for obtaining representative samples.
List the analysis methods used in the sampling analysis of the entire device, including the analysis methods of raw materials and products, as well as the relevant analysis methods of each section and system of the device.
Chemical production process package development
The chemical production process mainly includes two parts: reaction and separation. The reaction process is the core of chemical production, and the separation process is an important means to ensure product purity, both of which are indispensable.
The task of the reaction process is to determine the reaction route and obtain the best reaction conditions through parameter optimization. The following factors need to be considered in the selection of routes and conditions: yield, conversion rate, selectivity, energy consumption, safety, stability, medium corrosiveness (related to material selection), three wastes treatment capacity, equipment investment, operating costs, etc.
Common separations in chemical plants are gas-liquid separation, absorption, gas stripping, analysis, rectification, etc. The applicable working conditions of different separation methods are different. Trade-offs should be made in conjunction with material composition and separation requirements.