Process overview

In order to produce 100 000 tonnes/year of 1,3-Butadiene, the process of

oxydehydrogenation (Oxo-D Process) is selected. This production is proposed to build
a plant at Kaohsiung, Taiwan.

The process has three feed stream which is air, butene and steam. Steam is not
part of the reaction. The function of it is to avoid temperature rise in the process. Then,
those streams are feed into a reactor. This is where the process reaction occurs. After
the reaction, it goes into the first purification process to remove water steam by turning
it into liquid form and discharge into water treatment facility. Next, the purification
processes further remove nitrogen gas. The product produced then, entering third
purification process which is purification of nitrogen gas. After that, for last purification
process the product produce is sent to the distillation column to totally purify the
production of crude 1, 3 - Butadiene. In this column, it is successfully to separate crude
1, 3 - Butadiene with unwanted by-products by 99% purity.

4.5.1

First Mixer Control system

Controlled

Manipulated Variables

Disturbance

Control

Variables

System

Level

Drum

outlet

stream Change of liquid level Feedback

(stream 4)

Composition

inside the drum

Feed streams of the Change in composition

control

Ratio control

drum flow rate (stream

2 and 3)

4.5.2

Heat exchanger Control system

Controlled

Manipulated Variables

Disturbance

Control System

Variables

The

outlet The flow of steam supply Feed

temperature at from stream 1 must be stream 5

temperature

at Feedback
control

stream 6 must sufficient

be

in

350C

before entering
the reactor for
reaction
process

4.5.3

Reactor (CRV-100) Control system

Controlled

Manipulated Variables

Disturbance

Control System

Variables
Level

Outlet flowrate of hot Change of liquid level Feedback control

water

Flow

inside the drum

Feed streams of the Change in reaction rate

reactor

flow

Feedback control

rate

(stream 6)
Flow (Cooling The outlet temperature Low shell temperature Cascade control
water)

of the feed stream 7

(reaction temperature)

Pressure

The flowrate of outlet Increase of pressure at

feed stream 7

4.5.4

Feedback control

outlet pressure

Separator (V-101) control system

Type

Variable

Objective

Disturbance

Temperatur

The

To maintain the

Change of

temperature in

temperature of the

temperature in

the vessel

separator, stream 8

vessel

The flow of the

To maintain the flow of

Change in the

feed inlet

the feed inlet stream

flow inlet stream

stream

before entering the

Flow

Action

Cascade
Control

Cascade
Control

separator, stream 8
Level

The level in

To maintain the level at

Change in the

the vessel

the liquid stream.

product flow in

Functioning to control

inlet stream and

the high level and low

failure of liquid

level of the liquid in

stream

Feedback
Control

stream 9

Pressure

The pressure

To maintain the

Change in the

Feedback
Control

in the vessel

pressure of the

flow in inlet

separator before

stream and the

entering another

change of

equipment, stream 10

pressure in
vessel

4.5.5

Separator (V-102) control system

Objective (s)

Control

Manipulated

System

Variables

To maintain

Feedback

Liquid outlet

the level in the

control

flowrate

separator

Disturbances

Set Point

Inlet flowrate

H = 3.455 m

Inlet flowrate

P = 10.1325 bar

F = 9.326 kg/s

(stream 18)

To control the

Feedback

Vapour outlet

pressure in the

control

flowrate

separator

(stream 14)

To maintain

Feedback

Inlet flowrate

Change in inlet

the inlet

control

(stream 13)

flowrate

flowrate

4.5.5

Separator (V-103) control system

Objective (s)

Control

Manipulated

Disturbances

System

Variables

To maintain the level

Feedback

Liquid outlet flowrate

Inlet flowrate

in the separator

control

To control the

Feedback

Vapour outlet flowrate

Inlet flowrate

pressure in the

control

Inlet flowrate

Change in inlet

separator

To maintain the inlet

Feedback

flowrate

control

flowrate

4.5.6

Distillation column (T-100) control system

Control

Control

Manipul

Disturba

objectiv

variable

ative

nces

Control strategy

point

variable

To

The

The

The

Feedback control system

control

flowrate

flowrate

pressure

the

inside of of

flowrate

the

of

Set-

transmitter

the flowrate

and send the signal to the flow

column

at

the

14

controller to make corrective

stream

action and then the signal is

column

send to the powered control

distillatio

valve

n column

execute (Kister, 1990).

where

the

action

is

To

The

The

The

maintain

temperat

flowrate

temperat

the

ure

of

ure

of

of heating water is measured

temperat

inside

cooling

feed into

by respective transmitter. The

ure

the

water

the

temperature

inside the distillatio

into

column

reboiler

will 260 kg/hr

measure the flowrate of input

feed into n
the

flow

feed build-up,

into

the distillatio

The

Cascade control system:

the column

T=144.05

The temperature and flowrate

transfer

to

measured
the

is

temperature

indicator controller and then the

column

temperature will send the signal

to the flow controller. At the
flow indicator controller, the
flow is used together with the
temperature and flow to make a
corrective action before the
signal will be send to the
powered valve

To

The

The

The

control

level

of flowrate

temperat

Feedback control system:

The

flow

transmitter

will

the level flooding

of output ure

measure the level of liquid in

of

inside

stream

the column and send the signal

flooding

the

at

inside of

the the

to the flow controller to make a

6

inside the column

reboiler

column

corrective action and then the

column

signal will send to the powered

control valve where that action
is used to regulate the level
inside the column

To

The

The

The

Ratio control system:

control

refux

flowrate

pressure

There

will

Reflux

be

two

flow ratio = 45

the reflux rate into of

inside the

transmitter used in this type of

rate

column

control

the

recycle

column

condens

transmitter will measure the

ate

flow at the recycle stream and

into

system.

The

first

the

the second is to measure the

distillatio

flowrate at the output. The

flowrate that been measured at

column

the output is send to a ratio

controller. The ratio of both
streams is compared with the
set point and the signal is send
to the ratio indicator controller
for corrective action (Kister,
1990).

To

Level of The

Temperat

control

condens

ure

the level ate

flowrate

Feedback control system:

in of output inside the

The

level

measure

condens

transmitter
the

level

will
of

of

the

stream

condens

condens

from the er

and send the signal to the level

ate inside er

condens

controller to have the corrective

the

ate

action and the signal is send to

condensate in the condenser

condens

the

er

where the action take part.

To

The

The

Pressure

maintain

pressure

flowrate

of

the

inside

of

and

pressure

the

cooling

temperat

feed
the

powered

control

valve

Feedback control system:

The pressure transmitter will

P = 1.520
bar

measure the pressure of the

output of the column as the
7

inside the column

water

column

into

ure of the
the column

pressure represents the vapor

pressure and the composition

condens

of the vapor exit the column.

er

The signal is send to the

pressure controller to provide a
corrective action. The signal is
send to the powered control
valve where the action is used
to regulate the cooling water
flowrate in the condenser.