The stream report is the primary output of the process simulation program. If the process development is in a preliminary or final design stage, the stream report will be given to design engineers to size and design the equipment. To reduce their work, the stream report usually contains more than just flow rate, composition, temperature and pressure.
When the process is operating, the flowsheet will be a valuable reference for the operations group and for later debottlenecking and expansion studies.
What else to include
Enthalpy of each stream is given so heat balances can be readily calculated. Sometimes heat balance information is also available in unit operation reports by the simulator program, but the stream enthalpy should still be included in the stream report.
The equipment designers will also need density, heat capacity, viscosity and thermal conductivity of gases and liquids. These properties are used to compute the dimensionless groups used in correlations for heat transfer and mixing, as examples.
As mentioned above, the composition is required along with the temperature and pressure. These variables establish the state of the stream. Design engineers may require that information for their design programs . The composition may be given in terms of mass or molar fractions, or both. Regardless of the composition unit, total flow rate should be provided in both mass and molar units.
My stream report
The figure below shows an example of the stream report output. If a customer wishes additional stream information, the report function can be easily modified. The figure was made with the Mathcad zoom at 50% in order to fit the blog format.
My report function requires a range of stream numbers and the number of streams in a report partition. The output of the report function is a vector, M. Each element of the vector is one partition (i.e. one row of streams). The first example above shows one six-stream partition (the only one in this case) of M. It fits on a landscape A3, ANSI B (tabloid), or Arch B page with room to spare. It appears that these page sizes would accommodate eight streams. Additional streams can be accommodated with larger pages if desired. Larger pages may allow more than one row of streams. I haven't dealt with printed process flow diagrams for a number of years but I recall that ANSI D or Arch D sizes were common in the US. To avoid printing across a page break, elements of M can be placed on the pages as the page size allows.
I will assign high stream numbers to streams that don't represent a real process stream. An example is the tear stream, 74, shown in a previous post. The "real" stream is number 6 in this case. For my report and for the process flow diagram, I will provide only the "real" streams.
A closer look
The figure below was made at 75% zoom in order to make the report easier to read in this blog. The figure shows a two-stream partition, in this case the two feed streams.
The PPP program can have multiple phases in a stream, just as in a pipe in a process. In the example above, all streams have just one phase, either Vapor or Liquid. However, the density, viscosity, heat capacity, and thermal conductivity cells consist of two-element row vectors in case a stream has both phases. One element for each property is zero for the non-existing phase. The reader can determine by inspection of a single phase stream that the vapor value is given first, followed by the liquid value. The labels in the leftmost column also indicate this order, "V&L".
It's not fancy
The output doesn't have the fancy look with different fonts and colors that you might expect for a stream report. Instead, it just provides the basic information required
The Excel possibility
Exporting the stream information to Excel might be useful if other engineers need electronic access to the data and they don't use Mathcad. The Excel version would also make it possible to format the table in a more traditional fashion. The nested arrays in the report as shown can't be exported to Excel. However, if requested, it will take little effort to modify the report to eliminate nested arrays.
Where's the PFD?
Sometimes the process flow diagram (PFD) is placed at the top of a landscape sheet and the stream report is underneath. I have chosen to separate the PFD and the stream report for the following reasons.
First, for very large processes, multiple sheets are needed for both the PFD and the streams. Ideally the streams in a PFD drawing should match with the streams provided below. Achieving that could be a difficult task.
Second, combining the two would involve copying either the PFD or a row of streams and pasting into a sheet as an image. Resolution is often lost in this process. And, the copy process must be consistent so that the multiple images have the same zoom factor, i.e. fonts and symbols appear consistent.
Third, the complexity involved in combing the PFD and the stream report would have to be repeated every time either is changed. It is much easier to produce them separately and print each directly from their programs than via a copy and paste process.
I will include a post about my chosen PFD program when the process is complete.
 The large process simulation programs have added a lot of equipment sizing and mechanical design functions. This capability eliminates the manual transfer of stream data to special programs. However, experienced design engineers often have their own, preferred programs. Thus, the printed stream report with all of the state variables is needed.