Process Control Assignment

08 October 2024

Module : Process Control (PSCS101)

Examiner : Mr M. Shezi
Moderator : Dr T.P. Makhathini
Graduate Attribute Assessed : GA 9
Due Date : 25 October 2024
Marks : 100

This assignment is designed to assess this module's required graduate attribute, GA 9:

Independent learning. The GA will be evaluated using the attached rubric (last page of this
assignment). As stated in the learner guide, the GA must be achieved to obtain a duly
performed performance and qualify for the examination.

Optimization of Bio-oil and Ethanol Blends: Modelling, Control, and Evaporation

Strategies

1. Background

As 3rd year students at the Durban University of Technology (DUT), in partnership with
HexoFuels Solutions (HFS), you are tasked with optimizing the production process for bio-oil
and ethanol blends. DUT will provide a pilot-scale evaporator to help solve the challenges of
the current process before large-scale implementation.

The single-stage evaporator is located in the S3 basement lab at DUT. Currently, the mixing
tank operates under batch conditions; however, to improve the process, you must incorporate
continuous feeding of bio-oil and ethanol. In the current operation, bio-oil is mixed with
ethanol at a flow ratio of 4:1 in a mixing tank, creating a homogeneous solution. The inlet
flow rate of ethanol is given as 2 kg/s. This mixture undergoes a single-stage evaporation that
operates under atmospheric conditions. During the evaporation process, it is anticipated that
the evaporation rate of water will be approximately 3 kg/s, leading to the selective
concentration of ethanol within the mixture.

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2. Problem Statement

One of the critical challenges in this process is selectively removing water while retaining
ethanol in the bio-oil. Given that ethanol (boiling point 78 °C) has a lower boiling point than
water (100 °C), operating the evaporator to remove water without significant ethanol loss
presents a significant technical challenge. A vacuum evaporator was deemed unnecessary;
however, the single-stage evaporator must be optimized to achieve the desired ethanol
concentration while minimizing losses.

3. Modelling Assumptions

 Constant volume.
 The initial mass of ethanol in the mixing tank is 5 kg, the initial mass of bio-oil is 8
kg, and the tank volume is 10 m³.

Two essential chemical reactions occur during the mixing process: dehydration and
esterification. These reactions occur due to the variety of compounds present in the bio-oil.

a) Dehydration Reaction:
−1
Bio−oil+C 2 H 5 OH k d=0.1 s Dehydrated Biooil+ H 2 O
→

b) Esterification Reaction:
−1
Biooil+C 2 H 5 OH k e =0. 05 s Ester + H 2 O
→

4. Aim and Objective

To design, model, and optimize a process involving a heated mixing tank and single-stage
evaporator for blending ethanol into bio-oil while ensuring effective control strategies and
safety measures are implemented.

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5. Assignment Scope
5.1. Flow and Instrumentation Diagrams

You are required to develop a comprehensive Process Flow Diagram (PFD) and a Piping and
Instrumentation Diagram (P&ID) that illustrates the system design before and after control
implementation. Additionally, conduct a Hazard and Operability Study (HAZOP) to identify
potential hazards in the process and propose mitigation strategies. Develop a clear and
profound solution to the existing separation problems by employing process control
techniques.

5.2. Modelling and Plotting Requirements

You are required to:

 Develop mathematical models to describe the changes in mass and concentration of

ethanol over time, incorporating the exit conditions from the mixing tank.
 Plot the mass and concentration of ethanol versus time, visualizing how these
parameters evolve over time during the mixing process.
 Analyze the impact of the dehydration and esterification reactions on these dynamics.

5.3. Control and Safety Requirements

In addition to the above, you must incorporate the following aspects into your design:

 Control Strategies: Design control strategies to address the problem of selectively

removing water while retaining ethanol, including feedback, cascade, and feedforward
control loops for other process variables.
 Interlocks: Implement interlock systems to ensure safe operation, preventing
equipment operation under unsafe conditions (e.g., high temperature or pressure).
 Alarms: Design alarm systems to alert operators of critical conditions, which could
affect product quality and safety, e.g. low ethanol concentration.
 Energy Recovery Techniques: Propose energy recovery techniques to enhance
process efficiency.

NB: Justify your control scheme choices to ensure smooth operation and optimal product
quality.

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6. Summary of Requirements

 Process Flow Diagram (PFD): Illustrate the overall process flow, including key
equipment and material streams.
 Piping and Instrumentation Diagram (P&ID): Detail the instrumentation and control
systems associated with the mixing tank and evaporator.
 Mass and Concentration Models: Develop mathematical models to describe the
changes in mass and concentration of ethanol over time, and generate plots to
visualize these changes.
 HAZOP Report: Summarize potential hazards and recommended actions.
 Control Strategy Documentation: Present control loop designs with justifications for
each strategy chosen.
 Use Microsoft Excel or any other appropriate software plotting tool to generate your
modelling curves.
 The final report must be typed using MS Word (Font: Times New Roman, 12pt with
1.5 line spacing).
 All submissions must be done on MOODLE. NB: submissions must be done by one
member for each group. No resubmissions are permitted.
 The Turnitin similarity index must be less than 10% (excluding the cover page). If
your similarity is greater than 10%, do not prompt another member to submit. The
lecturer will carefully scrutinize the similarity report to check for possible plagiarism.
 Plagiarism is subject to harsh penalties, including suspension from the institution (as
stipulated in the learner guide). Ensure that you maintain originality, integrity, and
creativity.
 Only four (4) members per group are permitted.
 Ensure to go through the marking rubric thoroughly.

Good Luck!!!

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 RUBRIC FOR PROCESS CONTROL ASSIGNMENT
2024
Report Mark :_______
BNCME1 LEVEL 3– PCSC101
Late Penalty :_______

STUDENT/S INFO.

ASSIGNMENT TITLE
FINAL MARK

EXAMINER’S COMMENTS:

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ASSESSMENT CRITERIA Allocated % Examiner’s Mark % Moderator’s Mark
%
Standard Cover page/Title page 1.5
 Title of project
 Full name of authors and student numbers.
 A statement along the lines of ‘Submitted in partial fulfilment of the
requirements for the Process Control in the Department of Chemical
Engineering, Durban University of Technology’
Preface: 1
The following details have been included:
 where the work was carried out (e.g. S3 level 01, Steve Bike Campus,
DUT).
 Under whose supervision it was done, and over what period it was
conducted.
Declaration: 1.5
 A signed declaration by all members of project the report represents
their own work.
 Place and date of submission.
Acknowledgements: Contributions to the project by others have been 1
acknowledged:
 The work of one's supervisor/mentor.
 The support of any organization or institution which have helped.
 The active help of anyone not directly involved with the project
(colleagues, assistants).
1. Summary/Abstract 10
- State the purpose/objective of the project.
- State current process control systems being undertaken.
- State dynamic behavior (process modelling calculations procedure).
- State the achievement of assignment objective.
- State the technique adopted to retain the solvent in the bio-oil.
- State the conclusions reached and any recommendations for
improved operation.
2. Table of Contents -5
- Show the content topic and its page number.

3. Introduction 5
- Stated the relevance/importance of assignment topic.
- Stated the nature of the problem (using own words).
- Stated the approach adopted for the solution.
- Stated brief literature in support of chosen solution.
- State/Mention the objective and layout of the report.
4. Modelling, Plotting and Analysis 30
- Relevant scientific and engineering knowledge for formulating the
solution clearly stated/outlined.
- Comprehensive and accurate models provided.
- Clearly described changes in both mass and concentration.
- Equation editor used and equations numbered correctly.
- Provided clear, well-labelled plots that effectively show trends over
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time.
- Asymptotes are clearly indicated in the plots.
 DEPARTMENT OF CHEMICAL ENGINEERING
BACHELOR OF ENGINEERING TECHNOLOGY: CHEMICAL - (BNCME1)
2024
PROCESS CONTROL - PCSC101

STUDENT
SURNAME, INITIALS STUDENT NUMBER
SIGNATURE
STUDENT/S INFORMATION

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ASSIGNMENT TOPIC

DUE DATE

SUBMISSION DATE

EXAMINER/LECTURER

SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE PROCESS

CONTROL IN THE DEPARTMENT OF CHEMICAL ENGINEERING, DURBAN UNIVERSITY OF
TECHNOLOGY

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 2024 PCSC101 Assignment
NAMES___________________________________________________________ STUDENT NOS.:_____________________________________________