Part B: Explanation for Control Loop

Loop Control variable Manipulated variable

Number
101 Flow rate of fresh feed Valve of fresh feed
102 Level of vaporizer Vaporizer heat input
103 Reactor outlet temperature Temperature of molten salt
104 Temperature of process stream leaving reactor Generation rate of low-pressure
steam
105 Temperature of process stream leaving condenser Flow rate of cooling water
106 Level of flash drum Flow rate of liquid leaving the
bottom of vessel
107 Pressure in absorber Flow rate of off-gas
108 Ratio of water and gas feed coming into absorber Flow rate of water
109 Liquid level in absorber Flow rate of liquid leaving the
bottom of absorber
110 Flow rate of stream entering distillation column 1 Valve of stream entering
distillation column 1
111 Pressure in distillation column 1 Flow rate of cooling water of
condenser
112 Level of distillate receiver Flow rate of reflux
113 Pressure in distillate receiver Valve of the vent
114 Distillate flow rate Distillate composition controller
115 Temperature on stage 75 of distillation column 1 Reboiler heat input
116 Base level of distillation column Flow rate of bottom product
117 Flow rate of process stream into distillation Valve of stream into distillation
column 2 column 2
118 Pressure in distillation column 2 Flow rate of cooling water of
condenser
119 Level of distillate receiver Distillate flow rate
120 Ratio of reflux flow rate to column feed Reflux flow rate
121 Temperature on stage 17 of distillation column 2 Reboiler heat input
122 Base level of distillation column Flow rate of bottom product
Table of Summary:

Loop 101:
Objective: Control the flow of fresh feed (IPA and water) entering the vaporizer

Control Scheme: A change in the flow rate triggers the level transmitter, which leads the
controller to respond. The level controller either increase or decrease the valve opening.

Scenario: Increase in fresh feed flow triggers the transmitter, which sends signal to the
controller. The controller leads to narrowing of the valve and the fresh feed flow decreases.

Loop 102:

Objective: Control the level of vaporizer

Control Scheme: A change in level triggers the level transmitter and signal is transmitted to the
level controller. The controller regulates the valve of heat vaporizer input, either to increase or
decrease heat. Heat supplied is directly proportional to the rate of low-pressure steam produced.

Scenario: As the level of vaporizer increases, the level transmitter sends signal to the controller
to reduce the vaporizer heat input. The valve of the heat source is reduced, the heat energy
supplied decreases, and rate of steam produced decreases. The level of vaporizer decreases to
the set point.

Loop 103:

Objective: Control the outlet temperature of the molten salt

Control Scheme: A temperature control loop ensures the temperature of reactor outlet falls
within the range restricted. If disturbance occurs and the temperature is affected, the transmitter
signals the controller to regulate the valve to heat the molten salt. The molten salt temperature is
directly proportional to the rector outlet temperature, with the temperature of the feed entering is
constant.

Scenario: If the temperature of molten salt drops, the temperature control loop increases the
heat supplied to the molten salt. The transmitter signals the controller to widen the valve. More
heat is supplied to the molten salt and the reactor outlet temperature rises.

Loop 104:

Objective: Control the temperature of stream leaving the Heat Exchanger 1 (HX1) to condense
the fluid in the stream.

Control Scheme: A temperature sensor is installed at HX1 outlet. The temperature change is
detected by the sensor and signal is transmitted to the temperature controller. The temperature
controller decides, based on the set points, either to open or close the valve of the low pressure
steam stream of the heat exchanger.

Scenario: An increase in temperature above the set point is detected by the sensor and
transmitted to the controller. The controller widens the valve to increase the low pressure steam
generation rate, thus, absorbing more heat energy from the main stream and vice versa.

Loop 105:

Objective: Control the temperature of process stream leaving the Heat Exchanger 2 (HX2) in
order to store the fluid in the flash tank at a desire temperature.

Control Scheme: A temperature sensor is installed at the outlet of HX2. The temperature is
detected by the sensor and signal is transmitted to the temperature controller. The temperature
controller decides, based on the set points, either to open or close the valve which connects to
the cooling water stream of the heat exchanger.

Scenario: An increase in temperature above the set point of the HX2 outlet stream is detected
by the sensor and transmitted to the controller. The controller widens the valve to increase
cooling water flow rate which leads to more heat energy from the main stream and vice versa.

Loop 106:

Objective: Control the liquid level of the flash tank to prevent overflow or dry out.

Control Scheme: A level sensor is installed in the flash tank. The level change is detected by
the sensor and signal is transmitted to the level controller. The controller decides to either widen
or narrow down the valve of the stream location on the bottom of the vessel.

Scenario: A rise in the set point level is detected by the sensor and transmitted to the controller.
The controller widens the valve to discharge more liquid out of the vessel, thus, lowering the
liquid level back to set point.

Loop 107

Objective: To control the pressure of gas which is removed out from the absorber.

Control Scheme: A pressure sensor is installed in the absorber. The pressure of removed gases
(hydrogen and acetone) is detected by the sensor. When the pressure is varied away from the set
point, the pressure controller will control the pressure back to the desired pressure.
Scenario: The optimum pressure for the pressure of removed gas is 17atm. If the set point
pressure is too high or too low, the loss of acetone will increase which decrease the production
rate of acetone. Therefore, pressure at 17atm is most optimum for the minimum loss of acetone.

Loop108

Objective: To control the flow rate of the water entering the absorber.

Control Scheme: A flow rate sensor is installed in the absorber. The flow rate of the water into
the absorber from the top is detected by the flow rate sensor. When the flow rate is varied away
from the set point, the flow rate controller controls the flow rate back to the desired flow rate.

Scenario: The optimum flow rate of the water is 30kmol/h for the minimum loss of acetone. If
the flow rate is too high or too low, the loss of acetone will increase.

Loop 109

Objective: Control the liquid level of the flash tank to prevent overflow or dry out.

Control Scheme: A level sensor is installed in the absorber. The level change is detected by the
sensor and signal is transmitted to the level controller. The controller decides to either widen or
narrow down the valve of the stream location on the bottom of the vessel.

Scenario: A rise in the set point level is detected by the sensor and transmitted to the controller.
The controller widens the valve to discharge more liquid which lowers liquid level to set point.

Loop 110

Objective: Control the flow rate of stream entering distillation column 1.

Control Scheme: A flow rate sensor is installed at DC1 inlet. The flow rate change is detected
by the sensor and signal is transmitted to the flow rate controller. The flow rate controller
controls the degree of opening of valve based on the set points.

Scenario: The changes in flow rate is detected by the sensor and transmitted to the controller.
The controller decides either to open, partially open, close or partially close the valve to
maintain the flow rate within the set point.

Loop 111

Objective: Control the pressure by determining the heat amount to be removed from condenser.
Control Scheme: A pressure sensor is installed at the DC1 outlet. A pressure change is detected
by the sensor and signal is transmitted to the pressure controller. The pressure controller decides
either to open or close the valve which connects to the cooling water stream of the condenser.

Scenario: A rise in pressure exceeding the set point of the DC1 outlet is detected by the sensor
and transmitted to the controller. The controller opens the valve to increase cooling water flow
rate which leads to more heat to be removed and vice versa.

Loop 112

Objectives: Control the reflux level of the distillate receiver to prevent overflow or dry out.

Control Scheme: A level sensor is installed in the distillate receiver. The level change is
detected by the sensor and signal is transmitted to the level controller. The controller decides to
either widen or narrow down the valve of the stream.

Scenario: A rise in the set point level is detected by the sensor and transmitted to the controller.
The controller widens the valve to discharge more liquid out of the vessel, thus, lowering the
liquid level back to set point.

Loop 113

Objectives: Control pressure in distillate receiver by removing non-condensable gas in the vent.

Control Scheme: A pressure sensor is installed at the distillate receiver. The pressure change is
detected by the sensor and signal is transmitted to the pressure controller. The pressure
controller decides either to open or close the valve which connects to the vent.

Scenario: A rise in pressure exceeding the set point of the distillate receiver is detected by the
sensor and transmitted to the controller. The controller opens the valve of vent to remove the
non-condensable gas to lower the pressure.

Loop 114

Objective: Control flow rate of distillate from its receiver to monitor the distillate composition.

Control Scheme: A flow rate sensor is installed at distillate receiver outlet. The flow rate
change is detected by the sensor and signal is transmitted to the flow rate controller. The flow
rate controller controls the degree of opening of valve based on the set points.

Scenario: The changes in flow rate is detected by the sensor and transmitted to the controller.
The controller decides either to open, partially open, close or partially close the valve to
maintain the flow rate within the set point to control the composition of distillate and to maintain
the purity of product.

Loop 115

Objective: Control temperature of the stream on stage 75 of distillation column 1 to manipulate

the reboiler heat input.

Control Scheme: The temperature change is detected by the sensor on stage 75 of DC1 and
signal is transmitted to the temperature controller. The temperature controller decides, based on
the set points, either to open or close the valve which connects to the reboiler steam stream.
Scenario: An increase in temperature above the set point of the stream on stage 75 of DC1 is
detected by the sensor and transmitted to the controller. The controller widens the valve to
increase steam flow rate which leads to more heat energy for heating purpose and vice versa.

Loop 116

Objective: Control the liquid level of the distillation column 1 to prevent overflow or dry out.

Control Scheme: The level change is detected by the sensor at DC1and signal is transmitted to
the level controller. The controller decides to either widen or narrow down the valve of the
stream location on the bottom of the vessel.

Scenario: A rise in the set point level is detected by the sensor and transmitted to the controller.
The controller widens the valve to discharge more liquid out of the vessel, thus, lowering the
liquid level back to set point.

Loop 117

Objective: Control the flow rate of stream entering distillation column 2.

Control Scheme: A flow rate sensor is installed at DC2 inlet. The flow rate change is detected
by the sensor and signal is transmitted to the flow rate controller. The flow rate controller
controls the degree of opening of valve based on the set points.

Scenario: The changes in flow rate is detected by the sensor and transmitted to the controller.
The controller decides either to open, partially open, close or partially close the valve to
maintain the flow rate within the set point.

Loop 118

Objective: Control the pressure by determining the heat amount to be removed from condenser.
Control Scheme: A pressure sensor is installed at the DC2 outlet. The pressure change is
detected by the sensor and signal is transmitted to the controller. The pressure controller decides
either to open or close the valve which connects to the condenser cooling water stream.

Scenario: A rise in pressure exceeding the set point of the DC2 outlet is detected by the sensor
and transmitted to the controller. The controller opens the valve to increase cooling water flow
rate which leads to more heat to be removed and vice versa.

Loop 119

Objectives: Control the reflux level of the distillate receiver to prevent overflow or dry out.

Control Scheme: The level change is detected at the distillate receiver by the sensor and signal
is transmitted to the controller. It then decides to either widen or narrow down the stream valve.

Scenario: A rise in the set point level is detected by the sensor and transmitted to the controller.
The controller widens the valve to discharge more liquid out of the vessel, thus, lowering the
liquid level back to set point.

Loop 120

Objective: Control the reflux flow rate to manipulate the ratio of reflux flow rate to column feed.

Control Scheme: A flow rate sensor is installed at distillate receiver outlet. The flow rate
change is detected by the sensor and signal is transmitted to the flow rate controller. The flow
rate controller controls the degree of opening of valve based on the set points.

Scenario: The changes in flow rate is detected by the sensor and transmitted to the controller.
The controller decides either to open, partially open, close or partially close the valve to
maintain the flow rate within the set point to control the ratio of reflux flow rate to column feed.

Loop 121

Objective: Control the stream temperature on stage 17 of distillation column 2 to manipulate the
reboiler heat input.

Control Scheme: The temperature is detected by the sensor at stage 17 of DC2 and signal is
transmitted to the temperature controller. The temperature controller decides, based on the set
points, either to open or close the valve which connects to the steam stream of the reboiler.

Scenario: An increase in temperature above the set point of the stream on stage 17 of DC2 is
detected by the sensor and transmitted to the controller. The controller widens the valve to
increase steam flow rate which leads to more heat energy for heating the reboiler and vice versa.
Loop 122

Objective: Control the liquid level of the distillation column 2 to prevent overflow or dry out.

Control Scheme: A level sensor is installed in DC2. The level change is detected by the sensor
and signal is transmitted to the level controller. The controller decides to either widen or narrow
down the valve of the stream location on the bottom of the vessel.

Scenario: A rise in the set point level is detected by the sensor and transmitted to the controller.
The controller widens the valve to discharge more liquid out of the vessel, thus, lowering the
liquid level back to set point.