CHAPTER SEVEN

PROCESS CONTROL AND INSTRUMENTATION

7.1 OVERVIEW OF PROCESS CONTROL

Process control refers to the methods that are used to control process variables when
manufacturing a product. For example, factors such as the proportion of one ingredient to
another, the temperature of the materials, how well the ingredients are mixed, and the pressure
under which the materials are held can significantly impact the quality of an end product.

Process control refers to the regulation/ manipulation of variables influencing the conduct of a
process in order to obtain a product of desired quality and quantity in an efficient and economic
manner.

Process control is used together with the ideal sensor, signal processing, and actuation
technology, process control can enable the derivation of optimized process paths to make sure of
the attainment of robust process performance and high-quality end products despite inherent
process errors, variability, uncertainties, external disturbances, and noise.

7.2 OBJECTIVES OF PROCESS CONTROL

 The objectives of process control are:
 To maximize production and achieve desired output
 To maximize efficiency; by maintaining the process condition at the set points, efficiency
can be maximized.
 To ensure the safe operation of the plant at all times.
 To maintain low operating cost.

7.3 BENEFITS OF PROCESS CONTROL

 The benefits of process control are:
 Enhanced process safety
 Satisfying environmental constraints
 Meeting ever-stricter product quality specifications
 More efficient use of raw materials and energy
  Increased profitability

7.4 EQUIPMENT TO BE CONTROLLED AND THEIR CONTROL SCHEME

Equipment to be controlled includes but not limited to;

7.4.1 SAPONIFICATION REACTOR

Table 7.1: Control scheme around the saponification reactor

INSTRUMENT SAPONIFICATION REACTOR

PROCESS DESCRIPTION This involves the formation of soap that
occurs during biodiesel production.
CONTROL OBJECTIVE To obtain a desired quality and composition
of soap solution
DISTURBANCE The feed inlet flowrates, the temperature of
heat stream
CONTROLLED VARIABLES The flowrate of product, the temperature of
reaction.
MANIPULATED VARIABLES The feed flow rates, the heat stream
PROCESS CONTROL COMPOSITION The product composition is controlled by
CONTROL reducing the flow rate of the feed
Fig 7.1: Control around the Saponification Reactor

In saponification reactor the free fatty acids (oleic acid) within the waste cooking oil (WCO) are
to react with sodium hydroxide (NAOH) to form soap (Sodium Oleate) and water which can then
be removed from the oil (triglycerides). It is essential to reduce formation of soap that would
occur during the biodiesel production, else it will affect overall biodiesel purity at the end.

The process control algorithm around the saponification reactor is shown above (Fig 7.1). The
control objective, which is to obtain the desired quality and composition of the oil & soap mix
(shown in table 7.1) was achieved.
7.4.2 COMPONENT SEPARATOR
Table 7.2: Control scheme around the Component Separator

INSTRUMENT COMPONENT SEPERATOR 1

PROCESS DESCRIPTION The separator is used to remove the soap
(Sodium-oleate) and water, both which enter
the separator as a solution, from the oil.
CONTROL OBJECTIVE To obtain a satisfactory product or desired
composition.
DISTURBANCE The inlet feed composition and flowrate
CONTROLLED VARIABLES Flow rate and composition of output streams
MANIPULATED VARIABLES Flowrate of the input stream
PROCESS CONTROL COMPOSITION The product composition is controlled by
CONTROL regulating the flowrate of the soap solution,
either increasing or decreasing to achieve max
separation efficiency.
Fig 7.2: Control around the Component Separator

This is the component separator for the Soap solution mixture from the saponification reactor.
The soap causes an increase in viscosity, formation of gels which reduces ester yield and makes
the separation of glycerol difficult, therefore its removal will increase efficiency of the biofuel
production.

The soap solution enters the inlet and is separated into oil, with the soap removed going through
a different stream.

The process control algorithm around the component separator is shown above (Fig 7.2). The
control objective, which is to obtain the desire quality and composition of the purified oil (table
7.2) was achieved. This was done by varying the flowrate of the inlet soap solution, allowing an
efficient separation.
7.4.3 TRANSESTERIFICATION REACTOR
Table 7.3: Control scheme around the Transesterification Reactor

INSTRUMENT TRANSESTERIFICATION REACTOR

PROCESS DESCRIPTION Exchanging of alcohol from an ester by

another alcohol (conversion of Trilinolein and
Ethanol into Ethyl-linoleate and Glycerol in
the presence of aqueous Sodium Hydroxide
catalyst)
CONTROL OBJECTIVE To obtain a satisfactory product of desired
composition
DISTURBANCE The inlet feed rates and composition
CONTROLLED VARIABLES The flowrate and composition of the Ethyl-
linoleate and Glycerol product mixture
MANIPULATED VARIABLES The feed flowrate and ratio of ethanol and oil
PROCESS CONTROL COMPOSITION Either or both the flowrate of ethanol and oil
CONTROL can be regulated to obtain a product of good
and desired quality. The temperature control
is to control the temperature of the reaction.
Fig 7.3: Control around the Transesterification Reactor

Transesterification is the process of exchanging the organic group R” of an ester with the organic
group R’ of an alcohol, which in this case is conversion of Trilinolein and Ethanol into Ethyl-
linoleate. These reactions are often catalyzed by the addition of an acid or base catalyst, and an
aqueous Sodium Hydroxide catalyst is used to achieve 95% conversion of Trilinolein.

The process control algorithm around the Transesterification reactor is shown above (Fig 7.3).
The control objective, which is to obtain a satisfactory product of desired composition.
7.4.4 ETHANOL DISTILLATION COLUMN
Table 7.4: Control scheme around the Ethanol Distillation Column

INSTRUMENT ETHANOL DISTILLATION COLUMN

PROCESS DESCRIPTION The unreacted Ethanol from the previous
stream is separated from the reaction mixture
in this distillation column
CONTROL OBJECTIVE To obtain a satisfactory product of desired
composition
DISTURBANCE The flowrate of feed stream, the heat stream
CONTROLLED VARIABLES The flowrates of the output streams,
MANIPULATED VARIABLES The temperature of the heat stream, the
flowrate of feed stream
PROCESS CONTROL COMPOSITION The product impurity setpoints for both
CONTROL products may be modified, and the column
feed rate also adjusted to maintain purity of
products.
Fig 7.4: Control around the Ethanol Distillation Column

7.4.5 COMPONENT SEPERATOR 2

Table 7.5: Control scheme around the Component Separator 2

INSTRUMENT COMPONENT SEPERATOR 2

PROCESS DESCRIPTION The separator is used to remove the glycerol,
which enter the separator as a solution, from
the impure biodiesel
CONTROL OBJECTIVE To obtain a satisfactory product of desired
composition
DISTURBANCE The flowrate of input stream
CONTROLLED VARIABLES The flowrate and composition of the output
streams
MANIPULATED VARIABLES The flowrate and composition of the input
 stream
PROCESS CONTROL COMPOSITION The product composition is controlled by
CONTROL regulating the flowrate of the glycerol
solution, either increasing or decreasing to
achieve max separation efficiency.

Fig 7.5: Control around the Component Separator 2

7.4.6 BIODIESEL DISTILLATION COLUMN
Table 7.6: Control scheme around the Biodiesel Distillation Column

INSTRUMENT BIODIESEL DISTILLATION COLUMN

PROCESS DESCRIPTION The impure biodiesel from the previous
stream is separated from the reaction mixture
in this distillation column and produces the
pure biodiesel in the stream as the main
product
CONTROL OBJECTIVE To obtain a satisfactory product of desired
composition
DISTURBANCE The flowrate of feed stream, the heat stream
CONTROLLED VARIABLES The flowrate of feed stream, the heat stream
MANIPULATED VARIABLES The temperature of the heat stream, the
flowrate of feed stream
PROCESS CONTROL COMPOSITION The product impurity setpoints for both
CONTROL products may be modified, and the column
feed rate also adjusted to maintain purity of
products.
Fig 7.6: Control around the Biodiesel Distillation Column

7.4.7 NEUTRALIZATION REACTOR

Table 7.7: Control scheme around the Neutralization reactor

INSTRUMENT NEUTRALIZATION REACTOR

PROCESS DESCRIPTION This involves the neutralization of base in the
glycerol that occurs during biodiesel
production in the saponification reaction
CONTROL OBJECTIVE To obtain a satisfactory product of desired
composition
DISTURBANCE The feed inlet flowrates, the temperature of
heat stream
CONTROLLED VARIABLES The flowrate of product, the temperature of
reaction
MANIPULATED VARIABLES The feed flow rates, the heat stream
PROCESS CONTROL COMPOSITION The product composition is controlled by
CONTROL reducing the flow rate of the feed
Fig 7.7: Control around the Neutralization reactor
7.4.8 COMPONENT SEPERATOR 3
Table 7.8: Control scheme around the Component Separator 3

INSTRUMENT COMPONENT SEPERATOR 3

PROCESS DESCRIPTION The separator is used to remove the impure

glycerol, which enter the separator as a
solution, from the neutralization mixture
CONTROL OBJECTIVE To obtain a satisfactory product of desired
composition
DISTURBANCE The inlet feed composition and flowrate
CONTROLLED VARIABLES Flow rate and composition of output streams
MANIPULATED VARIABLES Flowrate of the input stream
PROCESS CONTROL COMPOSITION Either or both the flowrate of ethanol and oil
CONTROL can be regulated to obtain a product of good
and desired quality. The temperature control
is to control the temperature of the reaction.
Fig 7.8: Control around the Component Separator 3

7.4.9 GLYCEROL DISTILLATION COLUMN

Table 7.9: Control scheme around the Glycerol Distillation Column

INSTRUMENT GLYCEROL DISTILLATION COLUMN

PROCESS DESCRIPTION The Glycerol/Biodiesel mix that has been
formed is separated
CONTROL OBJECTIVE To obtain a satisfactory product of desired
composition
DISTURBANCE The feed inlet flowrates, the temperature of
heat stream
CONTROLLED VARIABLES Flow rate and composition of output streams
MANIPULATED VARIABLES The feed flow rates, the heat stream
PROCESS CONTROL COMPOSITION The product impurity setpoints for both
CONTROL products may be modified, and the column
feed rate also adjusted to maintain purity of
products.
Fig 7.9: Control around the Glycerol Distillation Column