Key points for reviewing chemical process packages
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A process package refers to all the technical documents that encompass the production technology for a chemical product. The process package, which represents the complete set of technologies related to a chemical process, is a documented expression of those technological achievements; it outlines the requirements that process technology imposes on engineering design, procurement, construction, and operational procedures, and serves as the main basis for preliminary design. The Sinopec’s \"Specifications for the Process Design Package of Petrochemical Plants (Comprehensive Technical and Process Package)\\" (SPMP-STD-EM2001-2015) is adopted in the industry. ‚ Foreign engineering companies have clear specifications regarding the contents of the process package. Although the contents are generally similar across different companies, they are not exactly identical, and sometimes appropriate modifications and additions are made according to the customer’s requirements.
The key points for reviewing a process package include the following aspects: 1. Process technology – advancement: Assess whether the process makes use of advanced technical concepts and whether it can be competitive within the industry, such as having advantages in terms of higher conversion rates or lower energy consumption. - Maturity: Determine whether there are successful application cases of this process in actual production, in order to avoid potential risks associated with the use of untested processes. 2. Process flow – Completeness: Check whether the entire process, from the input of raw materials to the production of the final product, is fully covered, including all intermediate steps such as reactions, separations, and purifications. - Reasonableness: Assess whether the process conforms to basic principles of chemistry, physics, etc., and whether the use of materials and energy is efficient and rational, for example, whether there are any unnecessary material cycles or energy losses. 3. Material balance – Accuracy: Verify that the calculations of material quantities entering and leaving each process are accurate, including raw materials, intermediates, products, and waste, to ensure compliance with the law of conservation of mass. - Key components: Pay attention to the material balance of major raw materials and key products to ensure that the flow and quantity of these essential substances are clearly defined. 4. Energy balance – Energy consumption analysis: Check whether the types of energy consumed during the process (such as electricity, heat, steam, etc.) and their quantities are clearly defined, and whether appropriate considerations have been given to energy-saving measures. - Energy recovery: Assess whether there are mechanisms for energy recovery, such as the effectiveness of waste heat recovery, in order to improve overall energy efficiency. 5. Equipment selection – Suitability: Check whether the type and specifications of the selected equipment meet the process requirements, such as whether the material of the reactor can withstand the corrosion caused by the reaction materials. - Reliability: Determine whether the equipment is supplied by reputable suppliers and whether its failure rate is within acceptable limits. 6. Safety and environmental protection – Safety measures: Check whether hazardous factors in the manufacturing process have been identified, and whether appropriate safety control measures are in place, such as explosion prevention and poison prevention measures. - Environmental protection requirements: Assess whether the methods used to treat pollutants such as wastewater, waste gas, and waste residues generated by the process comply with environmental regulations.
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