Mini Project Process & Dynamic Control

Based on the P&ID, five control objectives were discussed and listed below. The plant
chosen was production of Benzene.

1) Safety

The reactor has an operating pressure of 30 to 130 atm. If the pressure exceeds
130 atm, there is a safety relief valve which will open automatically by the
pressure exerted on the valve. The diverted gas will be directed to flare header
to burn the released substance and the combusted gas will be released to
atmosphere.

Ratio controller is used for the mixture of air and natural gas according to the
set point to make sure the combustion happens in the furnace is in correct
temperature. Without the ratio controller, the temperature can rise if the air and
gas mixture is high and can lead to hazardous situation and interrupt the
process.

2) Production Specification

Sulfolane solvent is introduced in solvent extractive distillation column with

naptha to increase the relative volatility between benzene and cyclohexane
which has the initial boiling point of 80.1 C and 80.7 C. Once naptha mix
with sulfolane, the boiling point of cyclohexane will be increased to ensure
pure benzene is yield from the process in distillation column or else traces of
cyclohexane will be mixed with benzene and 99% of purity cannot be
achieved.
 Reflux drum is attached after the condenser which is connected with
distillation column to achieve a more complete separation. Reflux drum works
as a distribution point for reflux and condensate. This process is to make sure
the pure product is sent for storage and the impure product is sent back for
process. This will maintain the quality of end product benzene.

3) Environmental Regulation

The gas released from the pressure relief valve is burned in the flare header to
ensure there is no air pollution happens when the gas is released to the
atmosphere based on Environmental Quality Act 1974 and Environmental
Quality (Clean Air) Regulation 1978.

4) Operational Constraints

The furnace is designed to heat the naptha up to 500C before entering the
reactor to ensure the process run smoothly. If the temperature is too high, it can
build up more pressure in the reactor and if the temperature is too low it can
damage the fixed bed catalyst in the reactor. High and low temperature alarm
has been installed to alert for any inconveniences.
 Hydrogen will be introduced to the naptha before pre-heated in furnace and
enter the reactor to ensure the life span of catalyst. Hydrogen is used to protect
the catalyst in the reactor and lengthen the life span of the catalyst. If the
naptha enters the reactor without hydrogen, it will reduce the life span and
efficiency of the catalyst (Silica-Alumina).

5) Economy

Based on the Table 1.1 below, Sulfolane has been chosen as the solvent for
extractive distillation column considering few factors. First are the power
needed to heat the solvent. Even though the price of the solvent is second
highest compare to others, the power needed to heat the solvent is the lowest
among the all which is only 2.4kWh per tan of feed. This will save a lot of
money for the utility and the next is the amount needed for the feed is 2:1
which is the second lowest compare to other solvent. This can save the amount
of solvent used for the feed and can give high return with low investment.

Table 1.1 Solvent