SUBJECT CODE & SUBJECT

PROCESS CONTROL (CPD20302)

TITLE OF MINI PROJECT

HYDRODEALKYLATION OF TOLUENE

NAME OF LECTURER
SIR. SYAHIDI FADZLI BIN ALFAN

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TABLE OF CONTENT

OVERVIEW........................................................................................................................3

INTRODUCTION...............................................................................................................4

SIMPLIFIED PROCESS FLOW DIAGRAM/PROCESS & INSTRUMENTATION

DIAGRAM..........................................................................................................................5-6

CONTROL STRATEGIES IDENTIFICATION AND EXPLANATION...........................7-8

ADDITION CONTROL STRATEGIES WITH EXPLANATION.....................................9-10

CONCLUSION...................................................................................................................11

REFERENCES ...................................................................................................................12

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1.0 OVERVIEW

This mini project was conducted as part of the Process Control (CPD20302), which covered
Benzene-Toluene fractionation and Benzene Distillation using Multivariable Control (MVC).
The Process Flow Diagram (PFD) and Process and Instrumentation Diagram (PID) were
provided by Google. Only a few symbols, such as valve controllers, fractionators, and
reboilers, appear on the PFD. More information is available in the P & ID, which includes
operational parameter controls at the input and output. Due to the high purity of both major
products, this system is significantly non-linear.

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2.0 INTRODUCTION

This mini project is completed as part of the Process Control course (CPD20302). The
procedure selected is hydrodealkylation of toluene, which removes the alky group from
Toluene to get Benzene. Google provided the Block Flow Diagram (BFD), Process Flow
Diagram (PFD) and Process and Instrumentation Diagram (P&ID). The Benzene-Toluene
fractionator at the plant is primarily used to separate Benzene via a distillation process.
Benzene-Toluene fractionation and Benzene Distillation with Multivariable Control (MVC)
applications are used in the process to create pure benzene. These control applications were
used to boost plant capacity and process efficiency. An aromatic extraction unit includes a
Benzene-Toluene fractionator. Aromatic extracts stream and steam stream are the two feed
streams. Liquid/liquid extraction is used to extract aromatics from an aromatics-rich stream.
In a distillation column, the benzene is separated from the aromatic extract and extracted as a
side-draw product. Benzene and toluene are the light and heavy main components,
respectively. Toluene will be disposed of at a landfill. Because these chemicals have a relative
volatility of about 2.5, this is a separation that requires a considerable reflux to feed ratio.
The feed stream is directed into the column by the flow controller. Any light hydrocarbons
contained in the extract are removed using pressure control. A control tray temperature
controller adjusts the benzene flow and resets the side-draw flow controller setpoint. The
bottom stream, which is regulated by the bottom's sump level controller, is where toluene and
other heavier aromatics escape the column. Reflux is managed by resetting a reflux flow
controller set point using a reflux drum level controller. A reboiler steam flow controller
controls the heat input to the column. The column has three manipulated variables (MVs) that
may be adjusted with this base level control method. The feed flow controller's setpoint may
be adjusted to match the amount of extract produced by the liquid/liquid aromatics extractor.
The reboiler steam flow controller setpoint is set to achieve the desired benzene product
purity via reflux, and the temperature controller setpoint is set to accomplish the desired
benzene recovery.
This system is substantially non-linear due to the high purity of both primary products.
Within the limitations, this suggests a high level of process sensitivity. The simpler the
control, the further one gets away from the constraints. It is simple for a human operator to
wander away from limits because of the low energy cost of departing from them and easier
control. This is where the chance for automated control exists. The PFD contains just a few
symbols, such as valve controllers, fractionators, and reboilers, but the P & ID has more
information, such as condensers, pumps, heat exchangers, and all valves, including operating
parameter controls at the input and output.

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3.0 SIMPLIFIED PROCESS FLOW DIAGRAM/PROCESS & INSTRUMENTATION
DIAGRAM

3.1 Block flow diagram (BFD)

Figure 3.1 Block flow diagram (BFD) of benzene distillation

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3.2 Process flow diagram (PFD)

Figure 3.2 Figure Process flow diagram (PFD) of benzene distillation

3.3 Process & Instrumentation Diagram (P&ID).

Figure 3.3 P&ID of benzene distillation

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4.0 CONTROL STRATEGIES IDENTIFICATION AND EXPLANATION
Control strategy (1) – Feedback Control

Figure 4.1 Toluene feed drum (V-101) uses feedback control

(Feedback control in Toluene feed drum).

The toluene feed drum's primary function is to verify that the benzene feed is correctly
mixed, and this information is used to understand how the system operates.

Figure 4.2: Heat exchanger (E – 101) with feedback Control

(Feedback control in heat exchanger)
The condensable gases in the reactor are separated from the non-condensable gases. The
lowest condensed liquids are received by the benzene tower. The overhead gases are captured
as fuel gases and used in other process units both upstream and downstream. The flash
process includes the phase separator as well as the heat exchanger (E-101).

Control strategy (2) – Cascade & Override Control

Figure 4.3 Fired Heater (H-101) uses cascade control

(Cascade control in fired heater).
The fired heater in Figure 4.3 is primarily used to pre-heat the reactor feed stream.
Combustion processes are taking place inside the heater. Air and fuel gases provide heat to
the burner. The air-to-gas ratio is crucial for good gas combustion. To enable full combustion
of all fuel gases, air is frequently given in excess.

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 Figure 4.4 Alkylation reactor (R-101) uses cascade control
Figure 4.4 shows a vapour-phase reactor with a reaction temperature range of 300 °C to 400
°C. The reactor effluent is then cooled via a heat exchanger using process cooling water. A
cascade control mechanism is used to regulate the reactor output composition, reactor
temperature, and fuel flow to the burner.

Figure 4.5 Benzene Column Tower (T-101) uses Cascade Control

(Cascade control in benzene column tower)
As demonstrated in Figure 4.5, all of the benzene components are separated from the heavier
toluene (benzene) in the benzene column tower. The lighter gases are also returned to the
reactor's input, while the ethyl benzene and other by-products are collected as bottom liquid.
Due to the dynamics of the Benzene column tower, extended dead periods and significant
analyser delays are conceivable. Following that, a slew of controllers may be required to
regulate the critical parameters and satisfy the design objectives of such a tower. As a result,
two cascading control loops and three single-loop controllers are employed.

Figure 4.6 Reflux liquid pumps (P-102 A/B) uses Override control
(Override control in Reflux liquids pumps)
Reflux liquid pumps collect liquid from the bottom of the accumulator and pump a portion of
it back (reflux) to a lower position in the column for reintroduction. By ensuring adequate
downward liquid flow to meet the rising vapour, the refluxing process enhances separation in
the column.

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5.0 ADDITION CONTROL STRATEGIES WITH EXPLANATION
5.1 FEEDBACK CONTROL

Figure 5.1 Block Diagram of Feedback Control

Because it monitors the controlled variable and gives it back to the controller within a loop,
the feedback control is a closed-loop control. The feedback loop aids in determining how well
the process has reacted to previous interventions. If previous modifications failed to yield the
intended result, the feedback control will make more adjustments. This procedure will
continue until the controlled variable's set point coincides with the set point of the controlled
variable. It turns the feedback control method into a self-correcting one.
Because it takes corrective action only when an error (the discrepancy between the controlled
variable and the set point) is created, feedback control is also known as reactive control.
Because of disturbance inputs, process parameter fluctuations, and inadequate modelling, an
error occurs.

5.2 CASCADE CONTROL

Figure 5.2: Block Diagram of Cascade control

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Cascade control, like override control, is a multiple loop control system that incorporates
more than one measurement and manipulation. Two control loops are used in the cascade
design to alter one process variable.
The main loop, which measures the controlled variable, has a controller that employs the set
point provided by the operator. The major or master loop is sometimes known as the outer
loop. The primary controller's output is used as the set point for the inner loop, which
measures an intermediate process variable (typically a large disturbance). Inner loops are
often referred to as secondary or slave loops. The secondary loop is useful for controlling the
primary process variable effectively.
5.3 OVERRIDE CONTROL
Override control, also known as selective control, is a type of multivariable control in which
many controllers can affect the same process and the controller selection is limited by a
constraint.
There would be at least two controllers in the override control arrangement: a regular and an
override controller. The process is controlled by the conventional controller during normal
operating circumstances, while the override controller is dormant. The override controller
takes control of the manipulated variable (known as the override variable) from the standard
controller through a selector after the specified constraint is achieved or exceeded. This
override operation ensures that the override variable does not exceed that limitation.
Specialized selection switches allow controller outputs to be switched smoothly without
disrupting the operation. The High Selector Switch (HSS) prevents a variable from reaching
its upper limit, while the Low Selector Switch (LSS) prevents it from surpassing its lower
limit.

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6.0 CONCLUSION

Hydrodealkylation processes were employed as a case study in this micro project. For these
hydrodealkylation processes, we have provided the Block Flow Diagram (BFD), Process
Flow Diagram (PFD) and Process and Instrumentation Diagram (P&ID from google as well
as several control mechanisms in the system. We also discover that each strategic control has
its own set of benefits and drawbacks.

The HDA process is similar to many other chemical processes in that it has a lot of chemical
components, a lot of unit operations, a lot of recycling streams, and a lot of energy
integration. The HDA process's steady-state design has been widely researched in the
literature, but there has been no quantitative investigation of its dynamics and control. A
comprehensive, nonlinear dynamic simulation of the complete system, including reactor, heat
exchangers, and distillation columns, was used to build and evaluate an effective base-level
regulatory control system. The influence of a number of design factors has been
demonstrated. When the steady-state economic optimum design, which consists of a large
feed-effluent heat exchanger and a small furnace, is adopted, control performance
deteriorates. In the HDA process, changing the production rate using the reactor inlet
temperature as the manipulator results in a loss of benzene product quality variability.
Furthermore, changing the reactor input temperature allows for bigger variations in
production rate than changing the recycling toluene flowrate.

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7.0 REFERENCES
[1] Balonek, C. M., Colby, J. L., Schmidt, L. D., AIChE Journal, Vol. 56, No. 4, pp. 979-988,
1987.

[2] Kovash, S. M., Patrick, R. E., Kmecak, R. A., US Patent, US3700745, 1972.

[3] Patrick, R. E., Kmecak, R. A., Kovash, S. M., US Patent, US3686340, 1972.

[4] Meidanshahi, V., Bahmanpour, A. M., Iranshahi, D., Rahimpour, M. R., Chemical
Engineering and Processing: Process Intensification, Vol. 50, No. 9, pp. 893-903, 2011.

[5] Grenoble, D.C., Journal of Catalysis, Vol. 56, No. 1, pp. 32-39, 1979.

[6] Jin, T., Xia, D. H., Xiang, Y. Z., Zhou, Y. L., Petroleum Science and Technology Journal,
Vol. 27, No. 16, 2009.

[7] Turton, R., Bailie, R. C., Whiting, W. B., Shaeiwitz, J. A., “Analysis, Synthesis and
Design of Chemical Processes”, Pearson Education Publishing, 3rd Edition, 2009

[8] https://dwsim.fossee.in/flowsheeting-project/download/project-file/47

[9] https://www.technologynetworks.com/tn/go/lc/view-poster-231850

[10] https://www.coursehero.com/file/48308178/MINI-PROJECT-PROGRESS-1pdf/

[11] https://instrumentationinnutshell.blogspot.com/2018/01/override-control.html

[12] https://instrumentationinnutshell.blogspot.com/2017/12/cascade-control.html

[13] https://instrumentationinnutshell.blogspot.com/2018/01/feedback-control.html

[14]https://folk.ntnu.no/skoge/puublications_others/apc-
book/other/Luyben_PWC/Luyben_PWC_15_HDA_Process.pdf

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