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Module 2

This document describes several process control problems involving distillation columns, reactors, and other unit operations. Problem 1 describes a distillation column with intermediate and bottom reboilers, and asks to draw the independent control valves and determine the steady-state degree of freedom. Problem 2 describes a reactor with an endothermic reaction and asks to control the furnace and reactor exit temperatures. Problem 3 describes a Petlyuk column and asks to draw control valves and determine degrees of freedom. The remaining problems provide additional details about control objectives for various unit operations.

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225 views

Module 2

This document describes several process control problems involving distillation columns, reactors, and other unit operations. Problem 1 describes a distillation column with intermediate and bottom reboilers, and asks to draw the independent control valves and determine the steady-state degree of freedom. Problem 2 describes a reactor with an endothermic reaction and asks to control the furnace and reactor exit temperatures. Problem 3 describes a Petlyuk column and asks to draw control valves and determine degrees of freedom. The remaining problems provide additional details about control objectives for various unit operations.

Uploaded by

ShahrizatSmailKassim
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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PROBLEMS FOR MODULE II

II.1 Sketch a distillation column with a vapor sidestream from the stripping section and an intermediate
reboiler that vaporizes liquid from a stripping tray located immediately above the vapor side draw
tray. The vapor from the intermediate reboiler is fed back into the column immediately above the
tray from where the liquid is drawn into the intermediate reboiler. The feed to the column contains
non-condensables which are vented from the reflux drum as vapor distillate. The usual liquid
distillate and bottoms are withdrawn from the column. The intermediate reboiler uses lowpressure steam while the bottom reboiler uses high-pressure steam. The condenser uses cooling
water for heat removal.
a) Draw all independent control valves for the column described above
b) Excluding the feed and column operating pressure, what is the steady state operating degree of
freedom of this column.
(Hint: Count total number of valves and discount valves used for feed flow, column pressure and
surge level controllers)
c) Draw a control concept diagram in which
Column top pressure is controlled by adjusting the vapor vent valve.
Reflux drum level is controlled by distillate flow.
Reflux is ratioed to feed rate
Low pressure steam to intermediate reboiler is ratioed to the column feed.
Vapor side-draw is adjusted to hold a stripping tray temperature constant.
Bottom sump level is controlled by adjusting high pressure steam flow to the bottom reboiler.
Bottoms is flow controlled
Low sump level overrides the low pressure steam flow to the intermediate reboiler.
High column pressure overrides both steam valves.
II.2 Gas feed to an adiabatic tubular reactor is heated to 700 F in a gas-fired furnace. The reaction is
endothermic. The exit temperature of the gas leaving the reactor is to be maintained at 600 F.
a) Sketch the process flow sheet with a valve on the gas feed and another valve on the furnace fuel
gas line.
b) Draw a control concept diagram that accomplishes the following:
Gas feed is flow controlled
Fuel gas to the furnace is flow controlled and ratioed to the gas feed rate.
The fuel to feed ratio is adjusted by a furnace exit temperature controller.
The setpoint of the furnace exit temperature controller is adjusted by a reactor exit temperature
controller.
Furnace exit temperature controller setpoint is not to exceed 750 F
High furnace stack-gas temperature should pinch the fuel gas control valve.
II.3 The Petlyuk column configuration for separating a ternary mixture into its nearly pure constituent
components is shown in the Figure.
a) Draw all independent control valves for the process
b) Excluding the throughput and column pressures, what is the steady state operating degrees of
freedom for the process.
c) Based on your understanding of the function of each of the 6 column sections, develop a
temperature inferential control structure for the Petlyuk column configuration.

Header

II.4 A compressor pressurizes gas in a gas-header, which supplies multiple downstream users. When
the downstream users demand is low, the compressor drive speed is adjusted to maintain the
surge drum (or header) pressure. If however, the demand exceeds a certain maximum limit, to
avoid overloading the compressor drive, the drive speed is adjusted to maintain the flow through
the compressor at the maximum limit. Draw an override control system that accomplishes the
above control objectives.
FC
User 1
FC
User 2
Surge
RPM
FC
Drum
User N-1
FC
User N
Figure.

Gas compression unit for downstream users

II.5 Sketch a control concept diagram for the exothermic chemical reactor (see Figure) with reaction
heat being used to generate steam.
Steam drum pressure is controlled by the steam valve
Condensate flow is ratioed to feed flow
Steam drum liquid level is controlled by adjusting the condensate to steam ratio.
Feed is flow controlled
Reactor liquid level is controlled product withdrawal.

Reactor temperature is controlled by adjusting the stem pressure controller setpoint


A high reactor temperature override pinches the reactor feed
A low steam drum level override pinches the reactor feed
Steam

Condensate

Feed

Product

II.6 Sketch the following control concept diagrams


Temperature in a reactor is controlled by manipulating cooling water to a cooling coil. Pressure in
the reactor is controlled by admitting a reactant gas feed into the reactor. A high temperature
override pinches the gas feed valve.
The reflux drum level is controlled by the reflux flow back into the column. Distillate is maintained
in ratio with the reflux. The ratio setpoint is adjusted by a rectifying tray temperature controller.
The temperature controller setpoint is adjusted by a distillate composition controller.
II.7 Sketch a control concept diagram for the distillation column shown in Figure with the following
information:
Reflux is flow controlled, ratioed to feed rate, and over-ridden by low reflux drum level.
Steam is flow controlled, with the flow controller setpoint coming from a temperature controller
that controls a tray temperature in the stripping section of the column. Low base level or high
column pressure pinches the steam valve.
Base level is controlled by bottom product flow rate.
Reflux drum level is controlled by distillate product flow rate.
Column pressure is controlled by changing the setpoint of the speed controller on the compressor
turbine. The speed controller output sets a flow controller on the high pressure steam to the
turbine.
A minimum flow controlled (anti-surge) sets the valve in the compressor bypass line to prevent
the flow-rate through the compressor from dropping below some minimum flowrate.

Bypass

Compressor

HP Steam

Distillate

Reflux
Feed

Steam

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