FACULTY OF CHEMICAL ENGINEERING TECHNOLOGY AND PROCESS

BKF3413 PROCESS CONTROL AND DYNAMIC

2019/2020 SEMESTER II

Title Assignment 1 : Production of Acrylic Acid From Propylene

Date of Submission : 6 March 2020

Lecturer’s Name: Dr Noor Asma Fazli Bin Abdul Samad

Section: 03

Group Members:

NO NAME ID

1 MOHAMAD HATTA AIMAN BIN MOHD KA17033

SALLEH
2 MUHAMMAD AIMAN BIN MD IZHAM KA17042

3 NUR FARAHAIN BINTI MOHD NASRUDDIN KA17214

4 AYU NADZIRAH BINTI ALIAS KA17202

 TABLE OF CONTENT

i) P&ID of ethanol production from corn stover

ii) Process description
iii) Control loops for each unit operation
iv) References
PROCESS DESCRIPTION:
Chemical-grade (CG) propylene is mixed with steam and air and fed to a two-step oxidation
reaction system. In the first step, the propylene is oxidized to acrolein and, in the second step, the
acrolein is oxidized to acrylic acid. Both steps are carried out in tubular, fixed-bed reactors. The heat
generated by the exothermic reactions is used to generate steam. The effluent from the reaction
system is sent to a quench tower, where the acrylic acid formed is absorbed in water. Part of the
residual gas obtained by the top of the quench tower is incinerated, with the balance being recycled
to the first-step reactor. The aqueous solution is sent to downstream units for product recovery.

The aqueous solution from the quench step is fed to an extractor, where the acrylic acid is
separated by liquid-liquid extraction with a solvent. The top portion of the extractor, containing the
acrylic acid, is sent to a solvent-recovery column to recover a two-phase overheads stream. This two-
phase stream is separated and the organic phase, containing the solvent, is recycled to the extractor.
The aqueous phase is mixed with the raffinate from the extraction step and sent to a raffinate stripper
to minimize the solvent losses. The bottom stream from the solvent-recovery column is then fed to
the crude acrylic-acid column, where a concentrated acrylic acid stream is obtained as the bottom
product. The column overhead stream, mainly comprised of acetic acid and light impurities, is sent to
a recovery column. The bottom stream from the recovery column is sent to the crude acrylic acid
column and the overhead stream is recycled to the solvent recovery column.

In the purification area, the concentrated acrylic acid stream from the crude acrylic acid
column is fed to the product column. In this column, ester-grade acrylic acid is obtained as the
overhead product. The column bottoms are sent to a dedimerizer to convert the dimer impurity,
formed in the process, back to acrylic acid. Finally, the product from the dedimerizer is sent to the
bottoms stripper column, where the heavy ends are separated and sent to waste.

C-101 : Air Compressor

Compress air at air feed inlet from P= 1 bar to P= 5 bar at T= 25 C

C-102 : Turbine

Change the energy form in stream 8 at T=91.47 C and P= 1.2 bar

C-103 : Turbine

Change the energy form in stream 22 at T= 138.99 C and P= 1.39 bar

E-101 : Reactor Feed Heater

Heat the feed streams from mixer from T= 102.12 C to T= 310 C at P= 4.3 bar

E-102 : Reactor Product Cooler

Cooldown the product of reactor R-101 to T= 160 C at P= 3.39 bar

E-103 : Cooler

Cooldown the bottom product of distillation column T-101 to T= 50 C at P= 1.2 bar

E-104 : Heater

Heat the top product of absorber T-101 to T= 125 C at P= 1.02 bar

E-105 : Cooler

Cooldown the distilled product of T-103 to T= 35 C at P= 0.14 bar

E-106 : Cooler

Cooldown the bottom product of T-103 to T= 139 C at P= 1.8 bar

E-107 : Cooler

Cooldown the stream 25 to T= 50 C at P= 0.97 bar

E-108 : Cooler

Cooldown the acetic acid at top product of T-105 to T= 40 C at P= 0.95 bar

P-101 : Pump

Control the pressure of T-103 top product at T= 35.08 C and P= 1 bar

P-102 : Recycle Pump

Control the pressure of recycle feed at T= 50.02 C and P= 1.2 bar

P-103 : Product Pump

Control the pressure of acetic acid at T= 40.01 C and P= 1 bar

R-101 : Tubular Reactor

Complete vapor phase oxidation of propylene at T= 310 C and P= 3.39 bar

S-102 : Acrylic Acid Storage

Stores the acrylic acid at T= 50 C and P= 2.3 bar

T-101 : Absorber Column

Recover acrylic acid and acetic acid

T-102 : Extraction Column

Extraction process of acetic acid and acrylic acid

T-103 : Distillation Column

Distillation process occured

T-104 : Solvent Recovery Column

Extraction of acrylic acid from water occured

T-105 : Purification Column

Distillation process occurred to separate acrylic acid and acetic acid

 Control loops for each unit operation

No. Stream No. Label Unit Operation Description

In Out
1. - 10 - LAH
LT
Controller Objective: To keep the level of the
LAL

LC
10 feed at a desired value set point

Types of controller: Feedforward Controller

Controlled Variables: Level of the feed.

Manipulated Variables: Inlet flowrate into

the mixer.

Disturbance: The flowrate of the outlet to the

mixer.

2. - 1 - LT S-97
Controller Objective: To keep the level of the
S-98
LAH feed at a desired value set point
LAL

LC
P-178 Types of controller: Feedforward Controller
P-179 P-180
V-48

E-45 Controlled Variables: Level of the feed.

Manipulated Variables: Inlet flowrate into

the mixer.

Disturbance: The flowrate of the outlet to the

mixer.

3. - 3 - S-103
LT
S-104
P-190
Controller Objective: To keep the level of the
LAH
LAL feed at a desired value set point
LC
P-191 P-192
V-51 Types of controller: Feedforward Controller
E-48

Controlled Variables: Level of the feed.

Manipulated Variables: Inlet flowrate into

the mixer.

Disturbance: The flowrate of the outlet to the

mixer.
4. - 4 - Controller Objective: To keep the level of the
feed at a desired value set point

Types of controller: Feedforward Controller

LT

LAH
LAL
Controlled Variables: Level of the feed.
4
LC
Manipulated Variables: Inlet flowrate into
the mixer.

Disturbance: The flowrate of the outlet to the

mixer.

5. 1 2 C-101 P-183 V-49 E-46 Controller Objective: To maintain the

P-184
flowrate of air feed.

S-100 Types of controller: Feedback Controller

P-181
FC Controlled Variables: Flowrate of outlet
P-182
stream (Stream 2).
FT
S-99

Manipulated Variables: Inlet flowrate of air

Air Compressor
feed into the compressor (Stream 1).

Disturbance: Pressure difference.

6. 2 5 - P-194 Controller Objective: To maintain the flow

3 rate of the outlet (stream 5) in the presence of
4 disturbances
E-49
P-196
P-195 P-197
LT
Types of controller: Feed Forward Controller
LAH
S-106
LAL
LC
Controlled Variables: Flowrate of the outlet
stream (Stream 5).
V-52
S-105
P-193
Manipulated Variables: Inlet flowrate of feed
(Stream 2, Stream 3 and Stream 4) into the
compressor.

Disturbance: Pressure difference.

7. 5 6 E-101 Controller Objective: To increase the
temperature of the feed from the mixer.
P-199
Hot
Fluid
V-53 Types of controller: Feedback Controller
P-201
P-200
E-50
S-108
P-202 Controlled Variables: Temperature of the
TC
outlet stream (Stream 6).
S-107
P-198
TT

Manipulated Variables: The amount of heat

supplied from the heater.
Reactor Feed Heater
Disturbance: The amount of temperature
supplied (Stream 5).

V-54
8. 6 7 R-101 P-204 Controller Objective:
1. To control the composition of acrylic acid at
purity over 99%.
LT E-51 S-109
2. To keep the level of the reactor at a desired
AC
value set point by adjusting the flow rate of the
LAH
LAL
S-110 bottom product.
S-112
AT

LC V-55
Types of controller: Feedback Controller
S-111 P-203 (Analyzer) and Feed Forward Controller
(Level).
P-205

Reactor
Controlled Variables: The level of the reactor
and the composition.

Manipulated Variables: The inlet flowrate

(Stream 6).

Disturbance: The flowrate of the outlet

stream (Stream 7).

9. 7 8 E-102 P-208 Controller Objective: To control (decrease)

the temperature of the outlet stream.
P-206
Types of controller: Feedback Controller
E-52 P-207
Controlled Variables: The outlet temperature
S-113 TT
V-56 (Stream 8).
S-114
Cold
Stream
P-210 TC Manipulated Variables: The amount of heat
supplied.
Reactor Product Cooler
Disturbance: The amount of temperature
supplied (Stream 7).
10. 8 9 C-102 FT
Controller Objective: To maintain the
P-211
flowrate of the outlet stream.
S-116

FC
Types of controller: Feedback Controller.

Controlled Variables: The outlet flowrate

S-115
V-57 (Stream 9).

Manipulated Variables: The inlet flowrate

(Stream 8).

E-53 P-212 Disturbance: Pressure difference.

Turbine
11. 9 11 T-101 To Wastewater Controller Objective: To obtain the desired
10 12 composition of acrylic acid.
AT

S-118
Types of controller: Feedback Controller.
P-214
AC P-215
Controlled Variables: The composition.

Manipulated Variables: The flowrate of the

S-117
stream (Stream 10)
V-58

Disturbance: No disturbance.
E-54

P-217

P-216

Absorber Column
13. 12 13 E-103 Controller Objective: To control (decrease)
the temperature of the outlet stream.
Cold
P-222 Stream

P-225
Types of controller: Feedback Controller
E-56
V-60
P-224
Controlled Variables: The outlet temperature
P-223
S-121
(Stream 13).
TC
Manipulated Variables: The amount of heat
S-122
supplied.
P-226
TT

Disturbance: The inlet temperature

(Stream 12).
Cooler
14. - - - LT Controller Objective: To keep the level of the
E-57
LAH
feed at a desired value set point.
LAL S-123 P-227

P-228
LC V-61 Types of controller: Feedback Controller
S-124

Controlled Variables: Level of feed.

Manipulated Variables: Inlet flowrate of the

feed.

Disturbance: Flowrate of the outlet to the

mixer.

15 28 14 - Controller Objective
33 • To maintain the level of mixture in
the tank
• To maintain the composition of the
mixture at the outlet stream

Types of controller
• Feed Back Controller

Controlled Variables
• Level of mixture in the tank
• Composition of mixture at the outlet
stream

Manipulated Variables
• The flow rate of the outlet stream
(Stream 14)
• The flow rate of the solvent inlet
stream (Stream 33)

Disturbance
The flow rate of inlet stream 26
16 13 15 T-102 Controller Objective
16 • To maintain the level of mixture in
the extraction tower

Types of controller
• Feedback Controller.

Controlled Variables
• The level of mixture in the tower
Manipulated Variables
• The flow rate of the outlet stream
(Stream 16)

Disturbance
• The flow rate of the inlet stream
(Stream 14 and 13)
The flow rate of outlet stream (Stream 15)

17 15 17 E-104 Controller Objective

• To control the temperature of the
outlet stream.
Types of controller
• Feedback Controller

Controlled Variables
• The temperature of the outlet stream
(Stream 17)

Manipulated Variables
• The flow rate of hot fluid supplied

Disturbance
The temperature of the inlet stream (Stream
15)
18 17 18 T-103 Controller Objective
19 • To control the temperature of the
outlet stream (Stream 18 and 19)
• Maintain the level of the mixture in
the distillation tower

Types of controller
• Feedback Controller.

Controlled Variables
• The temperature of the outlet stream
• The level of the mixture in the tower

Manipulated Variables
• The flow rates of the hot and cold
fluid supplied
• The flow rate of inlet stream (Stream
17)

Disturbance
The temperature of the inlet stream (Stream
17)

19 18 20 E-105 Controller Objective

• To control the temperature of the
outlet stream

Types of controller
• Feedback Controller

Controlled Variables
• The outlet stream temperature
(Stream 20)

Manipulated Variables
• The flow rate of the cold fluid
supplied

Disturbance
The temperature of the inlet stream (Stream
18)
20 20 21 P-101 Controller Objective
• To control the pressure of outlet
stream for ensuring a continuous
flow of mixture

Types of controller
• Feedback Controller

Controlled Variables
• The pressure of the outlet stream
(Stream 21)

Manipulated Variables
• Flow rate of the inlet stream (Stream
20)

Disturbance
No disturbance
21 19 22 E-106 Controller Objective
• To control the temperature of the
outlet stream

Types of controller
• Feedback Controller

Controlled Variables
• The temperature of outlet stream
(Stream 22)

Manipulated Variables
• The flow rate of cold fluid supplied

Disturbance
The temperature of the inlet stream (Stream
19)
22 22 23 C-103 Controller Objective
• To control the pressure of the outlet
stream
Types of controller
• Feedback Controller.

Controlled Variables
• The pressure of the outlet stream
(Stream 23)

Manipulated Variables
• The flow rate of the inlet stream
(Stream 22)

Disturbance
• No disturbance

23 23 24 T-104 Controller Objective

27 • To maintain the level of mixture in
the solvent recovery tower from
overflow
• To maintain the temperature of the
outlet stream (Stream 24 and 27)
• To control the composition of the
outlet stream (Stream 24 and 27)

Types of controller
• Feedback Controller.

Controlled Variables
• The level of mixture in the tower
• The temperature of outlet stream
(Stream 24 and 27)
• The composition of the outlet stream
(Stream 24 and 27)

Manipulated Variables
• The flow rate of the outlet stream
(Stream 24 and 27)
• The flow rate of the hot and cold fluid
supplied
• The flow rate of the inlet stream
(Stream 24 and 27)

Disturbance
• The temperature of the inlet stream
(Stream 23)
24 24 25 E-107 Controller Objective
• To control the temperature of the
outlet stream (Stream 25)

Types of controller
• Feedback Controller

Controlled Variables
• The outlet stream temperature
(Stream 25)

Manipulated Variables
• The flow rate of cold fluid supplied

Disturbance
The temperature of the inlet stream (Stream
24)
25 25 26 P-102 Controller Objective
• To control pressure of outlet stream
for ensuring a continuous flow of the
mixture

Types of controller
• Feedback Controller

Controlled Variables
• The outlet pressure of the stream
(Stream 26)

Manipulated Variables
• The flow rate of the inlet stream
(Stream 25)

Disturbance
No disturbance
26 27 28 T-105 Controller Objective
29 • To maintain the level of the mixture
in the purification tower
• To control the temperature of the
outlet stream (Stream 28 and 29)
• To maintain the composition of the
mixture in outlet stream (Stream 28
and 29)

Types of controller
• Feedback Controller.

Controlled Variables
• The level of mixture in the tower
• The temperature in the outlet stream
(Stream 28 and 29)
• The composition of mixture in the
outlet stream (Stream 28 and 29)

Manipulated Variables
• The flow rate of the outlet stream
(Stream 28)
• The flow rate of hot and cold fluid
supplied
• The flow rate of the inlet stream
(Stream 27)

Disturbance
The temperature of the inlet stream (Stream
27)
27 28 30 E-108 Controller Objective
• To control the temperature of the
outlet stream

Types of controller
• Feedback Controller

Controlled Variables
• The temperature of the outlet stream
(Stream 30)

Manipulated Variables
• The flow rate of the hot fluid
supplied

Disturbance
The temperature of the inlet stream (Stream
28)
28 30 31 P-103 Controller Objective
• To control the pressure of the outlet
stream for ensuring continuous flow
of mixture

Types of controller
• Feedback Controller

Controlled Variables
• Outlet pressure of the stream (Stream
31)

Manipulated Variables
• The flow rate of inlet stream (Stream
30)

Disturbance
No disturbance
29 29 32 E-109 Controller Objective
• To control the temperature of the
outlet stream

Types of controller
• Feedback Controller

Controlled Variables
• The temperature of the outlet stream
(Stream 32)

Manipulated Variables
• The flow rate of the hot fluid
supplied

Disturbance
The temperature of the inlet stream (Stream
29)
30 32 - S-102 Controller Objective
• To maintain the level of desired
product in the storage tank from
overflowing

Types of controller
• Feedback Controller

Controlled Variables
• The level of the product in the tank

Manipulated Variables
• The flow rate of the inlet stream
(Stream 32)
Disturbance
No disturbance
References
References

i) PFD slides from KALAM

ii) Process Dynamic and Control Textbook, Third Edition , Dale E. Seborg etc
iii) https://district.d303.org/
iv) https://www.instrumentationtoolbox.com/2011/05/how-to-construct-instrument.html
v) https://www.chemengonline.com/acrylic-acid-production-via-propylene-oxidation-
intratec-solutions/