Case Study On Automation Control Instrumentation

Navpreet Dhiman
Deparment Of Mechaincal Engineering
Rayat Bahra University
Mohali Kharar
Dhimannavpreet5757@[Link]
Abstract - This paper gives a review for Increase efficiency 3. Ensure safety B. The
industrial process integration with Pinch Importance of Process Control Refining,
Analysis and Software Tools for energy combining, handling, and otherwise
optimization. A brief case study at paper and manipulating fluids to profitably produce end
sugar industry was also made. The case study products can be a precise, demanding, and
shows that process integration plays a vital potentially hazardous process. Small changes
role in control and automation of industrial in a process can have a large impact on the
processes. The case study at paper industry end result. Variations in proportions,
proposes a design, to prevent the adulteration temperature, flow, turbulence, and many
mixture in getting mixed with pulp processing other factors must be carefully and
sector and to regulate the chlorine supply for consistently controlled to produce the desired
bleaching process. The case study at sugar end product with a minimum of raw materials
industry put forward a design to automate the and energy. Process control technology is the
konti machine, based on flow, current and pH tool that enables manufacturers to keep their
values which leads to the increase in operations running within specified limits and
efficiency of sugar and molasses separation to set more precise limits to maximize
process. Monitoring of pH value was profitability, ensure quality and safety. II.
implemented using LabVIEW. Keywords— PROCESS INTEGRATION It is a holistic
Process integration, Pinch Analysis, Pulp approach to process design and operation
processing, Bleaching process, Chlorine which emphasizes the unity of the process[4].
regulation, Separation process I. The main advantage of process integration is
INTRODUCTION A process denotes a series of to consider a system as a whole in order to
operation on fluid or solid during which improve their design and/or operation,
materials are placed in more useful state[1]. resulting in resource conservation. Process
Process as used in the terms process control Integration techniques applied the following
and process industry, refers to the methods of industrial issues: • Energy saving and GHG
changing or refining raw materials to create emission reduction • Debottlenecking of the
end products. The raw materials, which either critical areas in a given process • Optimization
pass through or remain in a liquid, gaseous, or of batch processes • Optimization of
slurry (a mix of solids and liquids) state during hydrogen use • Reactor design and operation
the process, are transferred, measured, improvements • Minimization of water use
mixed, heated or cooled, filtered, stored, or and wastewater production • Waste
handled in some other way to produce the minimization • Investment cost reduction •
end product. A. Process Control Process Increase plant controllability and flexibility
control refers to the methods that are used to There are two approaches to an integrated
control process variables when manufacturing process design.  First one is the Pinch
a product. For example, factors such as the concept for integrating energy (e.g., targeting
proportion of one ingredient to another, the heating and cooling utility consumptions) 
temperature of the materials, how well the Another one is the Mathematical
ingredients are mixed, and the pressure under Optimization approach (e.g., minimizing
which the materials are held can significantly effluent treatment flow rates in a wastewater
impact the quality of an end product. treatment system) III. PINCH ANALYSIS 28
Manufacturers control the production process International Journal of Engineering Research
for three reasons: 1. Reduce variability 2. & Technology (IJERT) IJERT [Link]
 Case Study On Automation Control Instrumentation
Navpreet Dhiman
Deparment Of Mechaincal Engineering
Rayat Bahra University
Mohali Kharar
Dhimannavpreet5757@[Link]
RTIA' 14 Conference Proceedings Pinch (PNS) [7] Solutions is a software package
analysis[10] is a methodology for minimizing where solving is based on P-graph approach.
energy consumption of chemical processes. It The P-graph framework has been introduced
deals with calculation of thermodynamically by Friedler et al. (1992) and further developed
feasible energy targets (or minimum energy for systematic optimal synthesis of industrial
consumption) and achieving them by processes. The aim of PNS is to examine the
optimizing heat recovery systems, energy feasible structures and select the optimum.
supply methods and process operating The optimal structure can be assessed in
conditions. The main objective of Pinch terms of cost, profit, etc. To define the
Analysis is to achieve financial savings in the optimal structure, both structural information
process industries by optimizing the ways in (which and how functional units are
which process utilities (particularly energy, connected) and sizing information are
mass, water, and hydrogen), are applied for a needed. The issues addressed by PNS
wide variety of purposes. The normal process Solutions are: (i) Representation of the
is shown in Fig.1 and the process using Pinch building blocks of a process network, (ii) The
Analysis is shown in Fig.2. Fig.1 Normal solution structures of the problem, (iii)
Process Fig.2 Process using Pinch Analysis A. Finding the maximal superstructure, (iv)
Possible Benefits: • Pinch Analysis will quickly Finding the optimal structure. This is a novel
identify where energy savings are likely to be tool for energy saving and pollution reduction.
found • Reduction of emissions • Pinch Waste-to-Energy (W2E) software is a
Analysis enable the engineer with tool to find supporting tool for technological process
the best way to change the process B. Pinch simulation. It has been developed in Java and
applications: Pinch analysis has been provides a user-friendly environment and
successfully applied to the following process intuitive operation. The principle of modelling
industries: • Oil refining (crude and vacuum and simulation is the same as in other similar
units, FCC etc) • Petrochemical • General systems. It creates a flowsheet, setting data
chemical • Food and Drink (mainly Dairy and and running simulation. W2E uses sequential-
Brewing) • Sugar (beet and cane) • Pulp and modular approach for computations. The
Paper • Specialty chemicals • Iron and steel main features are (i) Setting input data; (ii)
[Link] OPTIMIZATION AT INTEGRATED Checking computed values (temperature,
PULP AND PAPER MILLS . This work deals with enthalpy, and composition); (iii) Easy
energy optimization in evaporator and extension of new blocks and streams is
digester of integrated pulp and paper mills[9] possible. ProSim [8] is a leading European
in India, and recommends application of 7 chemical engineering software company
effects/plates evaporator in place of 5 delivering process simulation solutions to
effects/plates normally used. Steam economy process industries such as chemical,
resulting from this modification is definitely petrochemical, refining, oil, gas treatment,
more than 7. Pinch technology is found specialties chemical industries,
suitable for optimization of controlled pharmaceutical, food processing and energy
parameters in the digester. Using industries. Its activities also comprise
recommendations, total energy savings was engineering process consulting and custom
observed in West Coast Paper Mill (11.74%) software development. ProSim solutions are
and Star Paper Mill (12.97%). V. SOFTWARE used to improve process design, increase
TOOLS OVERVIEW Process Network Synthesis
 Case Study On Automation Control Instrumentation
Navpreet Dhiman
Deparment Of Mechaincal Engineering
Rayat Bahra University
Mohali Kharar
Dhimannavpreet5757@[Link]
plant efficiency and reduce their impact on
environment.