Lecture-6 - Process Controls in PTA Plant
Lecture-6 - Process Controls in PTA Plant
Process Controls
In PTA Plant
Industrial Revolution
1. 1760 to 1840 - Ushered in Mechanical production;
railways and steam engine.
3. Industrial revolution
Through the use of electronics
and IT further progression in
autonomous production
2. Industrial revolution
Level of complexity
Introducingmass production
lines powered by electric
energy
1. Industrial revolution
Introducing mechanical
production machines powered
by water and steam
Control Objectives:
– Safety
– Environmental Protection
– Equipment Protection
– Product Quality
– Profit Optimization
To OPTIMIZE A PLANT
Quality/ Economics Steady State
Operation
&
For Safety of Assets
Continuous
Improvement
Quality Policy & Business Policy
10-July-2022 Strictly Confidential 4
Important Characteristics of Process Control
In control Systems:
• A specific value (Set Point) is used as a desired value for the
controlled variable.
Set-point ε = Ts – T
F, T The value of deviation is sent to a control
Controller mechanism which decides what must be
done in order for the temperature to turn
Fi, Ti
back to the desired value.
hs
Fi, Ti Level Measuring
Device
F, T
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What To control
• Pressure
• Temperature
• Flow
• Level
• pH
• Speed
• Compressor Surge
• Slurry Concentration
• Weight ETC
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Recapitulation
Recapitulation: Process Flow Diagram
WWT
Atmosphere
Atmosphere
Comp. train
Atmospheric
Absorber
High
Pressure
Absorber
WWT
AIR
PX F/C
Rotary
Crystallizer Vacc. Filter
Post Hydrogenation
Oxidation Reactor
Oxidation Reactor
CTA Dryer Crystallizer PTA Silo&
Reactor Buffer/
CTA Silo 1st Decanter Packing
Conventional Distillation Slurry Tank
2ndDecanter
SV DV Computation MV Control
Block PROCESS
Valve
PV
Transmitter Sensor
Steam Similarly,
Several applications of
• Level Control
• Flow Control
• Pressure Control
ST Condensate • pH Control
10 -J uly -2022
Cold W ate r In
Strictly Confidential 15
ETC.
CASCADE CONTROL
L1 L2
DV PRIMARY/
MV DV SECONDARY/
SV CONTROL SECONDARY PRIMARY
MASTER SLAVE
CONTROL SV CONTROL VALVE PROCESS PROCESS
PV
PV
SECONDARY
TRANSMITTER
SENSOR
PRIMARY
TRANSMITTER
SENSOR
MV TC SV
802
A CASCADE CONTROL SYSTEM CONSISTS OF
PV
PRIMARY AND SECONDARY CONTROL LOOP.
TCE
DISTURBANCES OCCURING IN THE SECONDARY Master 802
(Primary)
(or SLAVE) CONTROLLER BEFORE THEY CAN AFFECT THE
Cold Oil Hot Oil
CONTROLLER VARIABLE OF THE PRIMARY LOOP.
SV
THE LATER IS CONTROLLED BY THE PRIMARY
PV FC
801
(or MASTER) CONTROLLER.
FCT
801
MV
Slave
(Secondary)
Furnace
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RATIO CONTROL
Fa
K=Fa/Fb
FC
Fb
PX IN PV
FC724
OUT
SV PID
MV
ML IN PV1’
FR725 FC726
SV1 IN OUT SET
MV1’ To Reactor
AA (Start Up
IN PV2’
IN
FR726
OUT SET
FC725
Sequence)
SV2
OUT
RATIO MV2 SV2’ PID
MV2’
CAT IN PV3’
FR721 FC721
IN OUT SET
SV3
OUT
10-July-2022
RATIO MV3 SV3’ Confidential
Strictly
PID
19
MV3’
Purpose of Process Control & Automation
To achieve operational Excellence & Optimum Profitability
To OPTIMIZE A PLANT
Quality/ Economics Steady State
Operation
&
For Safety of Assets
Continuous
Improvement
Quality Policy & Business Policy
10-July-2022 Strictly Confidential 20
CASE STUDY: Loss Optimization
PI764
Condenser
FC769
Top Press. FC769 Fluctuates
Reflux Top Product
Water + Trace RR
FC767
of AA (Loss) Fluctuates
Bottom Temp.
Fluctuates
TC764
Steam High AA loss
Bot.
Temp.
Normally AW contains
Bottom Product 0.8% AA; it reached
Stric tlAy +CoTnrafcideeonftW
A i alater
10-July-2022
up to 1.2% 21
•If D-1764 Stable
TC764, FC769,FC767 Stable
•PI764B Stable
P=450 P=250
I=40 I=5
D=0 D=0
AA concentration reduced
from 1.2% to 0.8%.
(1.2%-0.8%)*16.5T/h*8000h/Y
*1264$/T*75Rs/$
To OPTIMIZE A PLANT
Quality/ Economics Steady State
Operation
&
For Safety of Assets
Continuous
Improvement
Quality Policy & Business Policy
10-July-2022 Strictly Confidential 24
Process Flow Diagram
WWT
Atmosphere
Atmosphere
Comp. train
Atmospheric
Absorber
High
Pressure
Absorber
WWT
AIR
PX F/C
Rotary
Crystallizer Vacc. Filter
Post Hydrogenation
Oxidation Reactor
Oxidation Reactor
CTA Dryer Crystallizer PTA Silo&
Reactor Buffer/
CTA Silo 1st Decanter Packing
Conventional Distillation Slurry Tank
2ndDecanter
The Process Air Compressor train (PAC train): (a) Gas Turbine, (b)
All components are fixed coupled and therefore rotating always at the same
time.
10-July-2022 Strictly Confidential 27
Schematic Of Compressor Train
Steam Turbine
Gas Expander
Compressor
+30.6 MW
-27.8 MW
-14.0 MW
Motor/
Gear
Condenser Box
Genera
tor
Pe/Pa
IGV IGV
Min. Max.
Explanation
3
1. Inlet Guide Vane
(IGV) 2
2. Power Recovery
Valve (PRV)
3. Anti Surge Valve
(ASV)
DCS
3 Anti Surge
Switching over Switching over
Switching over
2TE