Unit 2143: Process Design and Control

1. Introduction to Process Design and Control

• Definition and scope of process design and control
• Importance in chemical, petrochemical, pharmaceutical, food, and other industries
• Basics of process engineering: concepts and terminology
• Role and types of control systems in process engineering

2. Process Flow Diagrams (PFDs) and Piping and Instrumentation Diagrams (P&IDs)

2.1 Purpose and Significance

• Overview and objectives of PFDs and P&IDs
• Differences and complementary roles in process design

2.2 Components and Symbols

• Standard symbols for equipment (reactors, pumps, heat exchangers, vessels)
• Instrumentation symbols and notation
• Lines and connections: process flow, utility lines, control lines

2.3 Equipment Identification and Process Relationships

• Tagging and numbering conventions
• Understanding unit operations and interconnections

3. Material and Energy Balances in Process Design

3.1 Concepts of Material Balances

• Conservation of mass principle
• Steady-state vs. transient balances
• Batch and continuous process considerations

3.2 Energy Balances

• First law of thermodynamics in processes
• Heat transfer concepts and calculations

3.3 Calculation Methods and Applications

• Solving balance equations
• Applications in process optimization and troubleshooting

4. Equipment Selection and Sizing

4.1 Selection Criteria

• Process requirements and operating conditions
• Material compatibility, capacity, and efficiency

4.2 Equipment Types

• Pumps: types, functions, and sizing
• Heat exchangers: design principles and selection
• Reactors: types and sizing considerations
• Distillation columns: fundamentals and design parameters

4.3 Practical Considerations

• Cost, maintenance, and safety factors

5. Process Control Systems

5.1 Control Loop Types

• Open loop vs closed loop control
• On-off, proportional, integral, derivative (PID) control

5.2 Controllers and Sensors

• Types of controllers and their applications
• Common sensors and measurement devices

5.3 Final Control Elements

• Valves, actuators, and control devices

5.4 Control Strategies

• Feedback control principles
• Feedforward control and combination strategies
• Maintaining process stability and efficiency

6. Process Safety and Hazard Analysis

6.1 Importance of Safety in Process Design

• Potential hazards in process industries

6.2 Risk Assessment Techniques

• Hazard and operability study (HAZOP)
• Failure mode and effects analysis (FMEA)

6.3 Safety Instrumented Systems (SIS)

• Components and functions
• Regulatory standards and compliance

6.4 Ensuring a Safe Operating Environment

• Safety culture and best practices

7. Process Optimization Techniques

7.1 Mathematical Modeling

• Model development and validation

7.2 Simulation Software

• Common simulation tools and their applications

7.3 Sensitivity Analysis

• Identifying key process variables

7.4 Parameter Optimization

• Strategies to improve efficiency, productivity, and cost-effectiveness

8. Case Studies in Process Design and Control

• Real-world examples from different industries
• Troubleshooting common process issues
• Implementing process improvements
• Optimizing system performance and outcomes