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UNIVERSITY OF LAGOS
Chemical Engineering Department
2019/2020 SESSION, 1st SEMESTER

CHG 501: Process Dynamics and Control

Tutorial 1a:
Introduction to Process Control
Date Given: Tuesday, January 28, 2020
Date Due: Monday, February 3rd, 2020
Test Date: Monday, February 3rd,
5:15 – 5:30 pm

Question 1-1
A process furnace (Figure 1-1) heats a process stream from near ambient temperature to a
desired temperature of 300oC. The process stream outlet temperature is regulated, by
manipulating the flow of fuel gas to the furnace, as shown below.

Figure 1-1 A Process furnace

a. What is the objective of this control strategy?

b. What is the measured output?
c. What is the manipulated input?
d. what are the possible disturbances?
e. Is this a feed-forward or feedback control system?
f. Discuss safety, environmental and economic issues, as it appertains to the process.

Question 1-2
The process shown in figure 1-2 is a distillation column used to separate a binary mixture
of methanol and water. It is desired to regulate the composition of methanol in both
overhead and bottoms product streams: xD and xB respectively. Let us assume that the
reflux flowrate L can be varied, but both overhead and bottoms product flow rates,
respectively, D and B, are determined by the steady-state material balance F = D + B.
The feed rate to the column F, as well as, the feed temperature T, is known to vary; Q is
the steam flowrate through the reboiler.
(a) Identity the output, manipulated (i.e. control), and disturbance variables of this
process.
(b) Assume that the feed temperature measurements are available, and that this
information is used to adjust the steam flow into the reboiler in order to control the
bottoms product composition. What type of control system configuration is this?
Will this be an effective way of regulating the value of xb? Explain what control
problems one might expect this control system configuration to suffer from.
(c) If the steam supply pressure variations become too frequent, what control system
configuration would you suggest to minimize the effect which such variations will
have on the regulation of xB? Sketch this configuration.

Figure 1-2 Binary distillation column

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Question 1 -3
Synthetic natural gas, SNG is produced by vapourising liquid butane and mixing the vapour with
compressed air. The mixture then flows to a packed bed reactor after it has been cooled in a heat
exchanger ( See figure 1-3). In order to meet control objectives of safety and quality control, the
following needs to be implemented:

The pressure in the vapouriser (P1), which is important for safety, should be controlled by
adjusting the vapour release from the vapouriser (v3); Liquid level in the vapouriser (L1), should
not overflow the vessel or drain empty, and this can be controlled by adjusting the flow of liquid
butane from storage to the vaporizer (v1); the percentage of butane in the mixed stream (A1),
which is important in order to avoid an explosive concentration, can be controlled by adjusting the
flow of air through the valve in the compressor suction, v4.

a. List the output (controlled) and input (manipulated and disturbance) variables.
b. Show the implementation of the above control schemes on a simple P& ID.

Figure 1-3 Production of Synthetic Natural Gas

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Question 1-4
Figure 1 - 4 shows reactants entering a jacketed CSTR where a reaction takes place and the
products exit. The reactor is cooled via a coolant water stream. The temperature inside the
reactor vessel is monitored via a sensor-indicator-transmitter device, which sends the signal
to a temperature controller which in turn controls a valve. The valve alters the flowrate of
the coolant water stream, thereby controlling the temperature inside the reactor. Reaction in
the reactor is in the gas phase, a pressure controller is therefore present to close the inlet
valve if the CSTR becomes too full (high pressure). The product is condensed and sent to a
storage tank. The tank contains a level controller at a set point on the top of the tank. If this
tank were to fill, materials would get clogged up in the reactor. Therefore, if the tank
reaches 90% of its total capacity, the level controller will send an electric signal, which
opens an emergency drainage line located at the bottom of the tank. The level controller will
also activate an alarm alerting plant engineers that there is a problem with the storage tank.
Finally, the level controller will also close the inlet valve to the storage tank.

Show the instrument diagram for the processing unit (CSTR + Storage vessel) above

Reactants

Cooling
water in
Cooling
water out

Products

Figure 1-4. The CSTR preceding the storage vessel

Question 1-5
When designing instrument diagrams for a plant, it is paramount to ensure a stable
operation of the plant so that all safety and environmental standards are met, while at
the same time ensuring product quality and quantity.
There are several errors in the P&ID of Figure 1-5, which shows a vessel where a liquid is
vaporized using heat transferred from steam passing through a surrounding jacket. The
errors/mistakes have been identified and explained below.

• Control valve V-1 should be after the pump, not before. Placing a pump after a
control valve takes away your control of the flow rate and can also damage the
pump if the valve is shut off while the pump is running.

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 • Vessel E-1 is only being monitored with a pressure control. This is not adequate
redundancy for process control. There should also be a temperature control (to
make sure the vessel is at an appropriate temperature for vaporization) and a
level control (to make sure the agitator is always submerged in liquid).
• Although the vaporization takes place at ambient pressure, there should be a
safety valve on the vessel. What if there is a malfunction and too much vapor is
produced?
• The input and output streams for vessel E-1 are not sufficiently labeled. The
source of input streams and destination of output streams should be specified to
ensure adequate control of a process.
• There should be a flow meter and control valve on the vapor stream exiting the
vaporization vessel so that you can monitor and control the amount of vapor
exiting.

Redraw the instrument diagram

Question 1-6
Develop the piping and instrumentation diagram (P&ID) for thecontrol system of
the process whose flowsheet and description is given below.
Note that different cases have been assigned to different groups.

Groups 1 & 2 - > Case I

Groups 3 & 4 - > Case II
Groups 5 & 6 - > Case III
Groups 7 & 8 - > Case IV
Groups 9 & 10 - > Case V

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Case I. For Groups 1 & 2

Ammonium Nitrate Prilling Plant Control System

Ammonium nitrate is a major fertilizer. The flow sheet shown below shows the
process for its manufacture. A weak solution of ammonium nitrate (NH4NO3) is
pumped from a feed tank to an evaporator. At the top of the evaporator there is an
ejector vacuum system. The air fed to the system controls the vacuum drawn. The
concentrated solution is pumped to a surge tank and then fed into the top of a
prilling tower. In this tower the concentrated solution of NH4NO3 is dropped from the
top against a strong updraft of air. The air is supplied by a blower at the bottom of
the tower. The air chills the droplets in spherical form and removes part of the
moisture, leaving damp pellets or prills. The pellets are then conveyed to a rotary
dryer where they are dried. They are then cooled, conveyed to a mixer for the
addition of an antisticking agent (clay or diatomaceous earth), and bagged for sale.

Ammonium nitrate prilling plant

Draw the necessary instrumentation to implement the following:

1. Record the flow of weak solution of NH4NO3 to the evaporator.
2. Control the level in the evaporator
3. Control the pressure in the evaporator. This can be accomplished by manipulating
the flow of air to the exit pipe of the evaporator.
4. Control the level in the surge tank.
5. Control the temperature of the dried pellets leaving the dryer.
6. Control the density of the strong solution leaving the evaporator

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Case II. For Groups 3 & 4

Natural Gas Dehydration Control System

Consider the process shown in the figure below. The purpose is to dehydrate the natural
gas entering the absorber; this is accomplished by the use of a liquid dehydrant (glycol).
The glycol enters the top of the absorber and flows down the column countercurrent to
the gas, picking up the moisture in the gas. From the absorber, the glycol flows through
a heat exchanger into the stripper. In the reboiler, at the base of the stripper, the glycol
is stripped of its moisture, which is boiled off as steam. This steam leaves the top of the
stripper and is condensed and used for the water reflux. This water reflux is used to
condense the glycol vapours that might otherwise be exhausted along with the steam.

Natural gas dehydration system

The process engineer who designed the process has decided that the following must be
controlled.
1. The liquid level at the bottom of the absorber.
2. The water reflux into the stripper.
3. The pressure in the stripper.
4. The temperature at the top third of the stripper
5. The liquid level at the bottom of the stripper.
6. Efficient absorber operation at various throughputs.[amount of dehydrant to be
used is a function of throughput]

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Case III. For Groups 5 & 6

Sodium Hypochlorite Bleach Preparation Control System

Sodium hypochlorite (NaOCL) is formed by

2NaOH + Cl2 → NaOCl + H2O + NaCl

The flow sheet below shows the process for its manufacture. The process is as
follows.

Sodium hypochlorite bleach process

Dilute caustic (NaOH) is continuously prepared, to a set concentration, by water dilution

of 50% caustic solution. This diluted caustic solution is stored in an intermediate tank.
From this tank, the solution is pumped to the hypochlorite reactor. Chlorine gas is
introduced into the reactor for the reaction.

Prepare an instrument diagram to accomplish the following:

1. Control the level in the dilution tank.
2. Control the dilution of the caustic solution.
3. Control the level in the bleach liquor storage tank.
4. Control the ration of excess NaOH/available Cl2 in the outlet stream from the
hypochlorite reactor.

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Case IV. For Groups 7 & 8
Control System in the Sugar-Refining Process
The processing units shown below, form part of the process to refine sugar. Raw sugar is
fed to the process through a screw conveyor. Water is sprayed over it to form sugar
syrup. The syrup is heated in the dilution tank. From the dilution tank the syrup flows to
the preparation tank where more heating and mixing is accomplished. From the
preparation tank the syrup flows to the blending tank. Phosphoric acid is added to the
syrup as it flows to the blending tank. In the blending tank lime is added. This treatment
with acid, lime, and heat serves two purposes. The first is that of clarification, that is, the
treatment causes the coagulation and precipitation of the no-sugar organics. The second
purpose is to eliminate the coloration of the raw sugar. From the blending tank the syrup
continues to the process.

Sugar refining process

The following variables are thought to be important to control.

1. Temperature in the dilution tank.
2. Temperature in the preparation tank.
3. Density of the syrup leaving the preparation tank.
4. Level in preparation tank.
5. Level in 50% acid tank. The level in the 75% acid tank can be assumed constant.
6. The strength of the 50% acid. The strength of the 75% acid tank can be assumed
constant.
7. The flow of syrup and 50% acid to the blending tank
8. The pH of the solution in the blending tank.
9. Temperature in the blending tank.
10. The blending tank requires only a high-level alarm
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Case V. For Groups 9 & 10
Sulphuric Acid Process
The figure below shows a simplified flow diagram for the manufacture of sulphuric acid
(H2SO4). Sulphur is loaded into a melting tank where it is kept in the liquid state. From this
tank it goes to a burner where it is reacted with the oxygen in the air to produce SO2 by the
following reaction:
S(l) + O2 (g) → SO2 (g)

From the burner the gases are then passed through a waste heat boiler where the heat of the
reaction of the above reaction is recovered by producing steam. From the boiler the gases
are then passed through a four-stage catalytic converter (reactor). In this converter the
following reaction takes place:
SO2 (g) + 
→ SO3 (g)
½O2 (g) ←

From the converter, the gases are then sent to an absorber column where the SO3 gases are
absorbed by dilute H2SO4 (93%). The water in the dilute H2SO4 reacts with the SO3 gas
producing H2SO4.
H2O(l) + SO3 (g) → H2SO4 (l)

The liquid leaving the absorber, concentrated H2SO4 (98%), goes to a circulation tank where
it is diluted back to 93% using H2O. Part of the liquid from this tank is then used as the
absorbing medium in the absorber.

Sulphur

Sulphuric acid Process.

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The following variables are thought to be important to control.
1. Level in the melting tank.
2. Temperature of sulphur in the melting tank.
3. Air to the burner.
4. Level of water in the waste-heat boiler.
5. The concentration of SO3 in the gas leaving the absorber.
6. Concentration of H2SO4 in then dilution tank.
7. Level in the dilution tank.
8. Temperature of the gases entering the first stage of the converter.

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 Grouping for Tutorial 1a
S/N Matric. No. NAMES (SURNAME FIRST) Tutorial Group
1 140811022 Okoh Kachukwu Emma
2 150401027 Aina Sodiq Babatunde
3 150401063 Olorunfemi Joshua Bamidele
4 150401102 Obi Onyema Steven
5 150409007 Etuk Uduak Friday
6 150409050 Aluejime Joseph Brown
1
7 160401519 Owoyele Aduragbemi O.
8 160401530 Owoade Tobiloba
9 160409503 Adetunji Oluwaseun Yommy
10 160409521 Fadipe Abdul-Wadud Ibukunoluwa
1 150401001 Busari Taofeek Ayinla
2 150401009 Jegede Samuel Babatunde
3 150401031 Ofili Patrick Onyebuchi
4 150401072 Faminigba Oluwaseyi
5 150401110 Adenuga Adetola David
6 150409008 Joseph Timothy O.
2
7 160401502 Ubah Chinelo Ijeoma
8 160401520 Sofidiya Oluwafunto T.
9 160409504 Akinyele Paul Ayomikun
10 160409524 Ikirigbe Ogheneovo Victor
1 150401003 Afolayan Philip Taiye
2 150401020 Okemuyiwa Olawale Oluwaseun
3 150401033 Fabusuyi Titilayo Valerie
4 150401090 Teslim Monsurat Abosede
5 150409009 Onyeali David Chinwueba
6 150409010 Ogbe-Nwori Ntito-Obari
3
7 160401504 Amoo Moyinoluwa A.
8 160401521 Ezeamalu Micheal Chukwudi
9 160409506 Okeke Jennifer Oluchi
10 160409525 Nureni-Balogun Hikmat Afolake
1 130401022 Ojo Samuel 'Similoluwa
2 150401004 Maku Uwasan
3 150401030 Odinikaeze Chukwuemeka Henry
4 150401041 Logunleko Ishaq Damola
5 150401092 Oyetunji Rebecca
6 150409014 Stephen Samuel Ochogbe
4
7 150409016 Yekini Yusuf Olaitan
8 160401506 Adimora Chukwuka Daniel
9 160401522 Olawuyi Kehinde Adisat
10 160409507 Oyetade Pelumi Adebola

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1 150401005 Adakole Dorothy A.
2 150401040 Aliu Aderinsola Paul
3 150401042 Alade Faruk Timilehin
4 150401094 Joseph Mayowa Olumuyiwa
5 150409017 Aniegboka Chima Jayjay
6 150409020 Olaosilo Samuel Opeyemi 5
7 160401509 Okwuba Mmesoma Jane
8 160401523 Shobowale Damilola Tosin
9 160409509 Talabi Oluwasanmi Olaife
10
1 150401010 Quadri Hikmat A.
2 150401043 Oladejo Ayomide Rabiu
3 150401044 Adelaja Taofeek Muhammad
4 150401099 Olumuyiwa Aanuoluwapo
5 150409018 Olayemi Toheeb Bolaji
6 150409022 Adesanya Iteoluwakiishi Bolu
6
7 160401512 Oyelade Oluwademilade E.
8 160401525 Alabi Ayotomiwa E.
9 160409513 Nwagu Ikechukwu Justin
10
1 150401011 Rasheed B. Izziyyah
2 150401045 Egbinola Mayowa Samuel
3 150401046 Idowu Aminat
4 150401522 Ebuehi Osaretin
5 150409025 Atundaolu Oluwapelumi Enoch
6 150409028 Sampson Esther Ekerete
7
7 160401513 Samuel Ilesanmi Olamide
8 160401528 Bobmanuel David Reginald
9 160409514 Olakunori Olabanjo Damilola
10
1 150401013 Adeniji Nazeer Ajibola
2 150401050 Lambert Somto Desmond
3 150401056 George-Adeniyi Adedolapo
4 150409001 Onyemachi Precious
5 150409031 Edafe Esiri Wilson
6 150409041 Oladipupo Awwal Damilare 8
7 160401515 Ndudi Emmanuel Ikechukwu
8 160401533 Cabel Egbuchulem O.
9 160409516 Odum Godwin Chukwuemeka
10

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1 150401015 Anibaba Ayoola Hakeem
2 150401057 Olisa-Akaeze Jemima U.
3 150401058 Olowookere Feranmi V.
4 150409003 Akinde-Peters Tosin Michael
5 150409047 Jimoh Musa Adinoyi
6 150409053 Olopade Tofunmi Joseph
9
7 160401517 Obi Chukwuwetalu W.
8 160401535 Obinna Michael Olugbenga
9 160409518 Bakare Abdulafeez Omotola
10
1 150401017 Williams Gloria Jumai
2 150401060 Michael Victor A.
3 150401087 Amzat Rukayat Ayomide
4 150409006 Aliyu Abdulqoyum Olamide
5 150409049 Oluwayomi Isaac Ayodeji
6 160401507 Oluyemo Kehinde Desola
10
7 160401518 Osibote Oluwatomisin D.
8 160409502 Echedom Chisom Bethany
9 160409519 Uwak Ruth Eno
10

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