What exactly is a chemical process package, as commonly referred to? What is included?
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The process package is primarily designed to address the issue of technical sources; it forms the basis for engineering design. For its details, refer to the specifications for process packages of petrochemical plants (comprehensive technical process packages) (SHSG-052-2003). In simple terms, a process package is the specific detailed description of the process operations. A process package is the same as a briefcase; it contains technical documents for reference and use by design institutes during the design process! A process package mainly includes data packages such as the process flow, basic process data, process operating parameters, key process calculations, and process equipment; hence it is commonly referred to simply as a process package. Simply put, with the process package, the design team can use it as a basis for the preliminary design, followed by the detailed design. As for the provider of the process package, it can be purchased by the owner or by the contracting party. Process software packages are generally developed by the providers of patented technologies (design institutes, research institutions, or clients) as a result of systematic research on a particular process technology; they provide guiding (principled) information regarding processes, equipment, and related process parameters (similar to the technical design practices used in China in the past). Based on the data from the process software package, along with the specific conditions of the site where the plant will be built, the engineering design for the project can be completed. If the process package does not come from the owner, then if Party A (the owner) wishes to use it, it must pay to acquire it and then provide it to the design institute for development. The process package is provided to the design institute for design purposes. It’s not necessarily required to be extremely detailed; you should provide as much information as is requested. Better companies offer process packages that are quite detailed, including information on reaction conditions, control schemes, and subsequent distillation processes, among other things. With this, the design institute can easily and accurately meet the owner’s requirements; some process packages consist of as many as seven or eight boxes of documents. With a detailed description of every aspect, the design institute can simply use this to create the drawings.
01 Which specialties are required to work together on the process package design? Process package development is a systematic engineering task. It involves multiple specialties and different disciplines, making it difficult to accomplish on one’s own. Generally speaking, the development and design of process packages are carried out by various specialties such as research and development, chemical engineering processes, process systems, analysis and testing, automatic control, materials science, safety and hygiene, and environmental protection, all working together to create the process package for the chemical product in question. 02 What design documents should be included in the finished process package? The finished products of the process package should include instructions, a process flow diagram (PFD), an initial pipeline and instrumentation diagram (PID), recommended equipment layout drawings, a list of process equipment, data sheets for the process equipment (with simplified diagrams of the equipment), summaries of catalysts and chemicals, a list of sampling points, a material manual (if required), a safety manual (including information on occupational health, safety, and environmental protection), an operation manual (including analysis manuals), a handbook of physical property data, as well as relevant calculation sheets.
1 Instruction Manual: The process package design instruction manual is an important part of the process package design and should include the following contents: a) Production methods, characteristics of the equipment； It describes the advancement, reliability of the process production methods used in the process package design, as well as the characteristics of the equipment. b) Product name and scale, annual operating hours, and plant operation mode, either on a five-shift three-shift rotation or four-shift three-shift rotation basis, or in some other manner. c) List the names of the various sections that make up the unit, in the order of the process sequence. d) List the names of the equipment and devices that generate the three types of waste, as well as the names, quantities, compositions, and emission forms of these wastes; provide explanations regarding the comprehensive utilization and treatment of such wastes. (1) Design basis: List separately the names and specifications of the raw materials, catalysts, and chemicals. List the names and specifications of utility services such as water, electricity, gas, and steam separately. (2) Process design: Describe the principles of the process, list the chemical reaction equations involved in the process (including primary and secondary reactions), and explain the catalysts used. In accordance with the sequence of the process, the process flow is described in detail by section and system (tower system, reactor system, compressor system). For each section and system (tower system, reactor system, compressor system), list the normal operating conditions for the key parameters, such as temperature, pressure, flow rate, composition, and the main control indicators. List the expected and guaranteed values for product specifications, production volume, and raw material consumption. List the main utility consumption indicators. It describes in detail the process control principles for each section and system (tower system, reactor system, compressor system), and explains the process safety interlock system. The selection of key equipment such as reactors, main mass transfer devices, main heat exchange equipment, and pumps is explained in terms of structure, form, material selection, etc.
2 Drawings: Process Flow Diagram (PFD), along with a material balance sheet； Piping and Instrumentation Diagram (P&ID) ； Suggested equipment layout diagram ； The recommended equipment layout plan should include the following: suggestions for the types of buildings and structures along with reference dimensions; the relative positions and elevations of the equipment (represented on a scale, without the need to indicate exact dimensions); the relative positions, elevations, or height differences of equipment with special requirements (exact dimensions must be specified); the names and tag numbers of all or the main equipment; and the relative locations of the control room and the main operation room.
3 Table: List of Process Equipment； Process Equipment Data Sheet (with equipment schematic) ； Summary Table of Catalysts and Chemicals ； Summary table of sampling points (if required) 4 Safety manual (including occupational health, safety, and environmental protection) Provides a brief overview of the main contents of the safety manual, its purpose for compilation, and its functions. Process description: Includes an explanation of the chemical principles and the process flow of the equipment. Detailed data on the basic physicochemical properties of raw materials, intermediate products, and final products, as well as information regarding fire, explosion, toxicity, etc., and the measures for controlling them. Measures and control methods taken to prevent accidents such as fires, explosions, and poisonings, based on the nature of the device. For example, regulations regarding ventilation, emergency exits, fire extinguishers, safety showers, eyewash stations, breathing equipment, and the provision of personal protective equipment. 5 Operation Manual (including the analysis manual, to be provided by the patent holder after all engineering design is completed) Provides a brief overview of the main contents of the operation manual, its purpose in being compiled, and its functions. Descriptions of chemical principles, plant process flows, and utility systems, along with scaled PFD and P&ID diagrams. List the recommended operating parameters for various units or systems (reactor systems, tower systems, compressor systems, etc.), as well as the effects of changing these parameters on the plant. It includes steps for conducting final inspections of equipment and piping machinery, procedures for lubricating valves and related mechanical components, steps for cleaning and purging equipment and piping, procedures for inspecting and calibrating instruments, and requirements for the commissioning and operation of pumps, compressors, and other equipment. Steps for driving, normal operation procedures, steps for normal and emergency shutdowns. Detailed normal and emergency shutdown procedures for process units and utility support systems. 6 Analysis Manual: Provides a brief overview of the main contents, purpose of preparation, and functions of the analysis manual, as well as the responsibilities, organization, and collaboration within the analysis department. A brief explanation of the basic requirements for sampling point design is provided, and the specific location, type of sampling point, analysis items, and analysis frequency for each sampling point in the entire system are listed in a sampling point summary table. The sampling procedures include the following aspects: safety measures for sampling operations, preparation of sampling containers, sampling steps as well as the preparation and processing of samples, and the techniques and methods for obtaining representative samples. List the analysis methods used for sampling and analysis of the entire plant, including those for raw materials and products, as well as the relevant analysis methods for various sections and systems of the plant.
04 Process package development for chemical production processes. Chemical production processes mainly consist of two parts: reaction and separation. The reaction process is the core of chemical production, while the separation process is an important means to ensure product purity; both are essential. The task of the reaction process is to determine the reaction pathway and obtain the optimal reaction conditions through parameter optimization. When selecting the route and conditions, the following factors need to be considered comprehensively: yield, conversion rate, selectivity, energy consumption, safety, stability, medium corrosivity (which relates to material selection), the amount of waste generated, equipment investment, operating costs, etc. Common separations in chemical plants include gas-liquid separation, absorption, stripping, desorption, distillation, etc. Different separation methods are suitable for different operating conditions. A trade-off should be made based on the material composition and separation requirements. "
For details, see SPMP-STD-EM2001
At the very least, it shows that one person cannot create a process package; since there are people online claiming to be able to provide such packages, it must be either pirated material or a form of deception.
Production process flow, required equipment, etc