Chapter 6 PROCESS CONTROL

Parameters such as temperature, pressure, level, and flow rates are crucial for a plant to achieve an optimum production with the necessary quantity and quality. To maintain operating conditions, thermocouples, pH meters, and level meters controllers are strategically positioned in the equipment. These controllers are connected to valves and openings to directly implement necessary changes. Each inlet stream is connected with a flow meter and a control valve to adjust the flow rate of the streams to achieve the requirements. The flow meters are installed after the pumps to measure the flow rate of the stream and send signals to the control valves that follow the pump to regulate the flow rate to achieve the required flow settings. The mixing tanks for the soaking of mango peel powder and for the culture medium preparation will be equipped with level sensors that relay feedbacks to the control valves. This is to maintain the fluid level and avoid overflowing.

25 101.325 9

FC

Glucose-rich filtrate
25 101.325 10 FC

T01

T02
pHC

Process water
25 101.325 11 FC

LC

Nutrients
90 101.325 TC 12

Culture medium

Heating medium

Mo1

To drain

LEGEND Temperature, C Pressure, kPa Stream number M01 FC TC LC Agitated tank Flow control Temperature control Level control pHC T01 T02 pH control Acid tank Base tank

Figure 6.1 Process control for dilution/sterilization tank M01

In Figure 6.1, feedforward control is applied to the flow controllers of the feed streams to the sterilization tank, a type of control that anticipates possible changes in the desired settings. A temperature controller is connected to a valve controlling the heating medium. A significant rise in the set temperature in the sterilization tank would prompt a change in the opening of the valve to decrease the flow of the heating medium. A level transmitter (LT) measures the level in the tank and transmits a signal associated with the level reading to a controller (LC). The controller compares the reading to a predetermined value, in this case, the maximum tank level established by the plant operator, and finds that the values are equal. The controller then sends a signal to the device that can bring the tank level back to a lower level a valve at the bottom of the tank. The valve opens to let some liquid out of the tank. The pH in the tank is also monitored and maintained at pH 5.3-5.5 by adding an acid or a base.

16 90 101.325 12 FC

Flue gas

Culture medium
25 101.325 13 FC

T03

T04
pHC

Inoculum
25 101.325 14 FC LC

Air

25 101.325 TC 15

Fermentation broth

Cooling water

R01

To drain

LEGEND Temperature, C Pressure, kPa Stream number R01 FC TC LC Fermenter Flow control Temperature control Level control pHC T03 T04 pH control Acid tank Base tank

Figure 6.2 Process control for fermenter R01

The fermenter in Figure 6.2 also uses feedforward control in the incoming culture medium, inoculum, and air streams. A level controller is used to maintain the level at the predetermined value and to avoid overflowing in the tank. A cooling medium is provided to absorb the heat released during respiration of S. cerevisiae in the fermenter. The cooling medium is used to maintain the temperature for optimum growth of the organism. Two pH controllers are each attached to acid and base tanks to adjust and maintain the pH at 5.3-5.5.