PRODUCTION

FINAL YEAR DESIGN PROJECT PRESENTATION 1

SUPERVISORS

OF SORBITOL PROF. MADYA DR. MASLI IRWAN ROSLI

DR. NOORASHIKIN MD SALEH
FADHLI OMAR (MTC FLOATING SOLUTIONS)
HEMAVATHI SILVAMANY (SIME DARBY)
YEOW EU LUN (FAETH ASIA PACIFIC)

FROM OIL
PALM FROND
GROUP 8
KAMAL AIKAL BIN DAHLAN
AHMAD NASRUL MUIZZ BIN AHMAD NAZRI
KHAIRUNNISA BINTI SHAMSULAZMIL
SWATIGA PANICKAR A/P GOPINATH PANICKAR
PUTRI NATASHA BINTI MEGAT JOHAR
 CONTROL CONFIGURATION OF
COOLER COOLER/HEATER
HEATER

Control Control Manipulated Control action Control Control Manipulated Control action
objective variable variable taken objective variable variable taken
To ensure the Temperature of Flow rate of When T > set To ensure the Temperature of Flow rate of When T > set
stream pass stream, T cooling water, point, valve stream pass stream, T cooling water, Fs point, valve
through is Fw opening through is opening
cooled enough increase. heated up decrease.
When T < set enough When T < set
point, valve point, valve
opening opening
decrease. increase.

Setpoint Temperature (℃) Type of valve Setpoint Temperature (℃) Type of valve
H-204 105 Diaphragm valve
H-201 230 Diaphragm valve
H-205 120 Diaphragm valve
H-207 55 Diaphragm valve H-202 230 Diaphragm valve
H-304 27 Diaphragm valve
H-205 120 Diaphragm valve
H-306 27 Diaphragm valve
 control configuration of steam explosion extraction
column (t-101)
Type of Control Control Manipulated Control Type of
Controller Objective Variable Variable Action valve
Temperature To maintain Column Inlet steam When T>SP, Diaphragm
controller the temperature flow rate valve opening valve
temperature increase.
of the When T<SP,
column valve opening
(T=200oC) decrease.
pH To maintain pH in the Flowrate of When pH<SP, Diaphragm
controller the pH in the column NaOH valve opening valve
column decrease. 
(pH=11 to When pH>SP,
11.5) valve opening
increase.

Pressure To maintain Pressure Outlet When P>SP, Diaphragm

controller the pressure inside the flowrate from valve opening valve
in the column stream 6 increase.
column When P<SP,
(P=15 bar) valve opening
decrease.
 
CONTROL CONFIGURATION OF CSTR
REACTOR (R-201)
Type of
Controller
Control Objective Manipulated Variable Control Action Type of
valve
Temperature To maintain the temperature Inlet temperature of Temperature transmitter Gate valve
of the reactor at 230°C cellulose in stream 16 will send signal to control
valve to control
temperature fluctuations
inside the reactor

Pressure To maintain the pressure
inside the reactor at 15 bar
pH To maintain the pH of the
reactor in acidic condition
Flow To maintain the flow of
cooling water into the jacket
of the reactor
Outlet pressure of stream 22
Inlet stream 19 containing
sulphuric acid
Inlet stream of cooling water
Pressure transmitter will Diaphragm
send signal to control valve
valve when the pressure is
higher or lower than the
set point
pH transmitter will send Diaphragm
signal to control valve valve
when the pH turns alkaline
Flow transmitter will send Diaphragm
signal to control valve to valve
control the flow of cooling
water when the
temperature of reactor is
no longer at set point
Control configuration of phase separator (S-202)

Type of controller Objective control Manipulated Control action Type of valve

variable variable
Level To control the level Outlet liquid flow Level transmitter Diaphragm valve
of liquid in phase rate from S-202 at will send a signal
separator, S-202 stream 31a. to the valve if level
of liquid in S-202 is
different from set
point

Pressure To control the Outlet vapor Pressure Diaphragm valve

pressure of vapor flowrate from S- transmitter will
in the phase 202 at stream 27a. send the signal to
separator, S-202 pressure relief
and avoiding valve to open and
overpressure and send the material
explode. to vent if the
pressure is higher
than the set point
Control configuration of ion exchange chromatography (S-204
Type of
and s-303)
Objective Manipulated Control action Type of valve
controller control variable variable

Analyzer To control the Outlet flowrate Analyzer Diaphragm

composition and of glucose at S- transmitter will valve
purity of glucose 204 and send signal to
at S-204 and sorbitol at S- the valve if the
sorbitol at S-303 303 at stream purity of
39 and 58 glucose and
respectively sorbitol is low
than set point

Level To control the Outlet flowrate Level Diaphragm

level of liquid in of fructose at transmitter will valve
ion exchange S-204 and send a signal
chromatography, mannitol at S- to the valve if
S-204 and S-303 303 at stream level of liquid in
38 and 56a S-204 and S-
respectively 303 is different
from set point
Control configuration of TRICKLE-BED REACTOR (R-301)
Control Control Manipulated Control action Type of valve
42 objective variable variable

50 To control the Outlet Flow rate of Temperature Diaphragm

temperature temperature of cooling water in transmitter will valve
of the reactor the reactor (set jacketed vessel send signal to
PT
point: 140 ) control valve when
45 the temperature of
reactor is higher
than the set point
and increase the
valve opening.
TT To control the Pressure inside Outlet flow rate Pressure Diaphragm
To control of
pressure the Pressure
the reactorinside
(set Outlet
from theflow rate
reactor Pressure
transmitter will Diaphragm
valve
pressure
the vapour of the reactor
point: (set
50 bar) from the reactor
at stream 45 transmitter
send signalwill
to valve
TC
the vapourin
presence point: 50 bar) at stream 45 send signal
control valvetowhen
PC presence
the reactorin control valve inside
the pressure when
C.w in R-301 45 the reactor the pressure
the reactor is inside
V-30144 C.w the reactor
higher than is
the set
out higher than
point and the set
increase
45 point and increase
the valve opening.
the valve opening.
V-302
P-301
Control configuration of HIGH PRESSURE SEPARATOR (S-
301) Control
objective
Control
variable
Manipulated
variable
Control action Type of valve
PC
V-304 46
To control the Pressure Outlet flow rate Pressure Diaphragm
pressure of inside the from the transmitter will valve
46 vapour separator (set separator at send signal to
PT presence in point: 5 bar) stream 46 control valve when
46 the separator the pressure inside
the separator is
45 higher than the set
point and decrease
the valve opening.
To control the Fluid level Outlet flow rate Level transmitter Diaphragm
LT
52
fluid level inside the from the will send signal to valve
contained in separator separator at control valve when
the separator stream 52 the fluid inside the
S-301 LC and avoid separator reached
52
52 leakage the desired level
51 set point and
increase the valve
V-303 opening.

P-303
CONTROL CONFIGURATION OF HYDROGEN
PURIFIER (S-302)
Control
objective
Control
variable
Manipulated
variable
Control action
taken
Type of valve

To control the Pressure in the Outlet flow rate of Pressure in hydrogen Globe valve
pressure in the hydrogen pure hydrogen purifier is detected and
hydrogen purifier purifier stream then a signal will be
sent to the pressure
at desired
controller. The
pressure measured pressure is
compared to the set
point. If the measured
pressure in the
hydrogen purifier is
different from the set
point, a signal will be
sent and outlet flow rate
of pure hydrogen
stream is regulated.
To control the Feed flow rate Feed flow rate to Flow rate detector will Diaphragm
feed flow rate to to the the hydrogen read the feed flow rate valve
the hydrogen hydrogen purifier of hydrogen purifier. The
signal will be sent to the
purifier at desired purifier
flow controller. If there is
flow rate. any deviation from the
set point, then flow
controller will send
signal to the final
element which valve to
regulate the flow rate by
adjusting the valve
opening.
CONTROL CONFIGURATION OF
COMPRESSOR (P-302)
Control Control Manipulated Control Type of
objective variable variable action taken valve
To ensure Pressure at Flow rate of Pressure Diaphragm
the desired outlet of product out transmitter valve
pressure at compressor of detects the
the outlet of compressor pressure
compressor deviation in
is reached compressor
and send
signal to
pressure
controller.
Pressure is
controlled by
regulating
the valve
opening at
outlet
stream.
CONTROL CONFIGURATION OF
EVAPORATOR (S-304)
Control objective Control
variable
Manipulated
variable
Control action taken Type of valve

To control the flow Flow rate of Flow rate of inlet The flow rate of the team is Diaphragm valve
detected, a signal is sent to the
rate of steam inlet steam steam flow controller. The measured
required to flow rate is then compared to
vaporize 80% water the set point. If there is any
from the complex deviations from the set point, a
signal will be sent to the final
solution element
which is control valve of
steam and the steam flow rate
is regulated
To control the Pressure in the Outlet flow rate of Pressure in evaporator is Diaphragm valve
detected and then a signal will
pressure in the evaporator vaporized water be sent to the pressure
evaporator at controller. The measured
desired pressure pressure is compared to the
set point. If the measured
pressure in the evaporator is
different from the set point, a
signal will be sent and outlet
flow rate of vaporized is
regulated.

To control the feed Feed flow rate Feed flow rate to the Flow rate detector will read the Diaphragm valve
feed flow rate of evaporator.
flow rate to the to the evaporator The signal will be sent to the
evaporator at evaporator flow controller. If there is any
desired flow rate. deviation from the set point,
then flow controller will send
signal to the final element
which valve to regulate the
flow rate by adjusting the valve
opening.
 LAWS and regulations
EQA 1974 act 127 OSHA 1994 OSHA 1994 Factory and
(CIMAH 1996) Machinery 1967

An act relating to the Define the general duties of •

• Every manufacturer who
prevention, abatement, employers, employees, the
undertakes an industrial
control of pollution self-employed, designers,
and enhancement of activity shall aware of an
manufacturers, importers
the environment imminent danger
and suppliers of plant or
• Establish and maintain a
substances
good management
system for controlling
any major accident
EQA 1974 Act 127 • All hazardous materials
shall be listed with their
EQA 1974 (scheduled waste) regulation 2005 quantity less and equal
EQA 1974 (industrial effluent) regulation 2009 or more than their
threshold value, ceiling
EQA 1974 (clean air) regulation 2014
limit, eight-hour time-
weighted averaged.
An act to manage safety
and health problems
associated with
manufacturing industries.
• To provide for control
factories with respect to
matter relating to safety,
health and welfare of any
persons at work.
• Reactor, valve, heater
distillation column and
others are designated
based on specification
 HIRARC - PLANTWIDE
Hazard Identification Risk Assessment Risk Control

Likelihood

Severity

Risk
Unit process Work activity Hazard Effect Existing risk control measures Additional measures

 Wearing PPE – protective helmets,

General workplace Regular housekeeping Slippery floor Physical injury 2 1 2 -
goggles, safety boots
maintenance  
   
 Wearing PPE – protective helmets,  Prepare railings
Falls from extended height Physical injury 2 4 8
goggles, safety boots
 Buddy system

 Wearing PPE – protective helmets,

Untidy workplace Physical injury 3 2 6 -
goggles, safety boots
 Wearing PPE – protective helmets,  Make covers of
Regular machine Unguarded machine, no warning labels Physical injury 3 3 9
goggles, safety boots the gears of
maintenance machine
 Buddy system
 Have the start/
stop button
covered
 Wearing PPE – protective helmets, -
Cleaning tanks/vessels Confined spaces – low oxygen levels, Physical injuries, health 3 3 9
goggles, safety boots
  high temperature concerns  Buddy system
 
 Wearing PPE – protective helmets, -
Falls from extended height Physical injury 2 4 8
goggles, safety boots
 Buddy system
 Wearing PPE – protective helmets, -
Inhalation of toxic gas/fumes Asphyxiation 3 4 12
goggles, safety boots and also protective
masks
 Buddy system
 Limit the exposure to heat -
Hot workplace conditions Unbearable temperature for human Health concerns – fainting, 3 3 9
 Buddy system
body to withstand dehydration
 Rotating shifts -
Work ethics Unnecessary Psychological stress Health concerns 3 3 9
 Flexible working hours and day-offs
overtime/work hours
 HIRARC - EQUIPMENTS
Hazard Identification Risk Assessment Risk Control

Likelihood

Severity

Risk
Unit process Work activity Hazard Effect Existing risk control measures Additional measures

 Hydrolysis  Install high pressure alarm  Ensure no ignition

R-201 CSTR Overpressure Explosion 3 5 15
Reaction  Shut down plant when limit overpressure source nearby
Reactor        Increase thickness of reactor to withstand  Regular maintenance
 Pumping in the pressure and inspection
 
Sulphuric acid  Automatic shutdown system
   
 
 Pumping in water
 
 
 Pumped out gas
and liquid product
 
 
 
 
 Wall rupture  Install high temperature alarm
Overtemperature 3 4 12  Regular maintenance
 Reactor  Increase thickness of reactor to withstand
  surface the high temperature and inspection
become hot  Automatic shutdown system
   
 Install level indicator  Ensure no ignition
Pipe leakage and liquid Product from reactor 4 2 8
 Install alarm system source nearby
overflow will spill out  Regular maintenance
 
and inspection
 

 Wearing PPE – protective helmets,  Regular maintenance

Pipe leakage and release of Asphyxiation - 3 5 15
goggles, safety boots and inspection
high toxicity gas suffocation, may lead to  Install gas leakage indicator
  death  Install alarm system
 
 Hazard Identification Risk Assessment Risk Control

Likelihood

Severity

Risk
Unit process Work activity Hazard Effect Existing risk control measures Additional measures

 Install high pressure alarm  Regular maintenance and

R-301 Trickle-bed Reaction of glucose Overpressure inside reactor Explosion 2 5 10
 Shut down plant when pressure inspection
reactor into sorbitol over-limit  Ensure no ignition source
 Automatic shut-down plant nearby
 
 
 
 
Pumping of glucose Pipe leakage – spilled chemical Physical injury Install alarm system 4 1 4 • Regular check-up and inspection
into reactor
 Install alarm system  Regular check-up
Flow of hydrogen gas Pipe leakage – release of Flammable 2 5 10
 Shut down plant when pressure
 Ensure no ignition source
into reactor hydrogen gas over-limit
 Automatic shut-down plant nearby

 Install high pressure alarm  Regular check-up and

  Rupture of hydrogen gas Explosion 2 5 10
 Shut down plant when pressure inspection
tank/cylinder over-limit
 Ensure no ignition source
 Automatic shut-down plant
nearby

Catalyst poisoning Less effective in reaction Less pure product Periodically change the catalyst inside the 4 1 4 • Regular check-up and inspection
reactor
 HAZARD ANALYSIS
Chemical hazard identification
Chemical Acidity Alkalinity Explosiveness Flammability Toxicity Corrosiveness
Sodium hydroxide No Yes Yes (Heat release No Yes Yes
resulting in fire or
explosion risk)

Sulphuric acid Yes No Yes (May explode if No Yes Yes

heated)
Hydrogen gas No No Yes (May explosion Yes (highly No Yes
in mixtures with air flammable)  
and oxygen)
Sorbitol No No Yes (Finely dispersed Yes No No
particles form
explosive mixtures in
air)
Mannitol No No Yes (Finely dispersed No No No
particles form
explosive mixtures in
air)
Fructose No No No No No No
Black liquor No No Yes (May explode if No Yes Yes
heated)
Oligosaccharides No No No No No No
5-HMF No No No No No No