6.

Process control
6 1. Introduction:-
Control in one form or another is an essential part of any chemical
engineering operation. In all processes, there arises the necessity
of keeping flows, pressures, temperatures, compositions, etc.
within certain limits for reasons of safety or specification. It is
self-evident that automatic control is highly desirable,as manual
operation would necessitate continuous monitoring of the variable
by a human operator and the efficiency of observation of the
operator would inevitably fall off with time. Furthermore,
fluctuation in the controlled variable may be too rapid and
frequent for manual adjustment to suffice.
In its simplest form, the control of a process is most often
accomplished by measuring the variable it is required to control
(the control variable), comparing this measurement with the value
at which it is desired to maintain the controlled variable (the
desired value or set point), and adjusting some further variable
(the manipulated variable), which has a direct effect on the
controlled variable
In order to desing a control system to operate not only
automatically but efficently ,it is frequently necessary to obtain
both the steadystate and dynamic (unsteady state ) relationships
between the particular variabes involved . The manner in which
this information is obtioned is dependent largely upon the process
one or more types of control .e.g. single or multiple feedback
loops. Adative control, combined predictive and feedback
arrangements, distributed architectures , optimal control ,etc. the
use of the more modern and complex control systems is feasible
only because of the development of the microprocessor and, as
aresult, control has been one of the areas of major growth in the
process industries over the last twenty years. This growth is
reflected equally in the very substantial changesthat have
occurred in the plant control room and in the methods of
presentation of information to process operator [5] .
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6 2. Elements of control system:-
1- process:-
It is like mixer, tank, heat exchanger, stirrer tank reactor,
distillation column, etc
2- Measuring elements:-
Is the elements used to measure the value of the controlled out put
3- Control elements:-
Consists of two parts:
* Comparator:-
It receives the measured values and compares between setpoint
and measured value ,if the different between then zero this means
that the system operating ideally ,but if there is a different (more
or less than the setpoint) it send a signal to the controller .
* Controller:-
It the part that receive the signal from the comparator and analysis
it to gives the control signal that travel to the final element of the
control system, it is like proportional control, proportional
integral control, proportional derivative control and proportional
integral derivative control.
4- Final control element:-
It the part that makes changes into the process in order to lowers
or finished the error, it is like control valve, heater, etc.
Types of control systems:
Level control (LC) .
Pressure control (PC) .
Temperature control (TC).
Flow control (FC) . [5] .
1. Plant location:
The geographical location of the final plant can have a strong
influence on the success of an industrial venture .
Much care must be exercised in choosing the plant site, and many
different factors must be considered.
Primarily, the plant should be located where the minimum cost of
production and distribution can be obtained, but other factor, such
as room for expansion and general living condition, are also
important.
An approximate idea as to the plant location should be obtained
before a design project reaches the detailed estimate stage , and
affirm location should be established upon completion of the
detailed estimate design . The choice of the final site should
first be based on a complete survey of advantages and
disadvantages of various geographical areas and ultimately on the
advantages and disadvantages of available real estate . The
following factors should be considered in choosing a plant site:
1- Raw materials
2- Markets
3- Energy availability
4- Climate
5- Transportation facilities
6- Water supply
7- Waste disposal
8- Labor supply
1 Raw materials:
The source of raw materials is one of the most important
factors influencing the selection of a plant site. This is particularly
true if large volumes of raw materials are consumed, because
location near the raw materials source permits considerable
reduction in transportation and storage charges.
Attention should be given to the purchased price of the raw
materials ,distance from the source of supply , freight or
transportation expenses , availability and reliability of supply
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purity of the raw materials , and storage requirements .
2- Markets:
The location of markets or intermediate distribution centers
affects the cost of product distribution and the time required for
shipping. Proximity to the major markets is an important
consideration in the selection of plant site, because the buyer
usually finds it advantageous to purchase from near by sources . It
should be noted that markets are needed for by products as well as
for major final products.
3- Energy availability:
Power and steam requirement are high in most industrial plants
and fuel is ordinarily to supply these utilities. Consequently,
power and fuel can be combined as one major factor in the choice
of plant site. Electrolytic processes require a cheap source of
electricity, and plants using electrolytic processes are often
located near large hydroelectric installations. If the plant requires
large quantities of coal or oil, location near a source of fuel
supply may be essential for economic operation. The location cost
of power can help determine weather power should be purchased
or self- generated
4- Climate:
If the plant is located in a cold climate, costs may be increased by
necessity for construction of protective shelters around the
process equipment , and special cooling towers or air
conditioning equipment may be required if the prevailing
temperatures are high . Excessive humidity or extremes of hot or
cold weather can have a serious effect on the economic operation
of a plant. And these factors should be examined when selecting a
pant site.
5- transportation facilities:
Water, railroads, and high ways are the common means of
transportation used by major industrial concerns. The kind and
amount of product and raw materials determine the most suitable
type of transportation facilities.
The plant site should have access to all three type of
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transportation , and , certainly , at least two type should be
available there is usually need for convenient air and rail
transportation between the plant and the main company
headquarters , and effective transportation facilities for the plant
per sonnet are necessary .
6 Water supply:
The process industries use large quantities of water for cooling
washing, steam generation and as a raw material, therefore, must
be located where a dependable supply of water is available.
Located near the source of water like river or lake.
7- Waste disposal:
A given area has no restrictions on pollution; waste disposal can
be accomplished by water land or air dispersal.
8- Labor supply:
The type and supply of labor available in the vicinity of a
proposed plant site must be examined.
In referring to the previous factors , we have chosen Eden city as
a place for this plant due to the following :
Availability of all transportation means: air crafts , marines &
land transportation.
Aden is a free zone, and this will improve the external trade.
Aden has a strategic site in the country .
Availability of men power , where in Aden there is a lot of
Labors in addition to a large number of engineering institutes
which help to increase the engineering knowledge for Labors and
other people , because of this there are a lot of medium
education people in Aden
Availability of utilities
as power supply , water and fuel .
Availability of raw materials (there is a petroleum refinery)[5].
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7 2. Plant layout :
The layout of the plant includes the following :
Storage area :
This area including the stores of raw material and the products, it
is situated in a proper safe and isolated from labors but not for
from the production site in order to decrease the costs of
transportations.
plant area :
In this area there are tools and equipments that make the
manufacture process & these tools should be situated in a place
suitable for the productive process & putting in consideration the
possibility of extensions in the future.
Work shop and power supply station .
Stores .
Administration and staff offices and Training office .
Laboratories :
which include chemical Laboratory and control room .
Service area :
which include restaurant , mosque , break place and first aid .
Extinguishment area :
to put out fire .
Car Parking .