BKC3433 PROCESS CONTROL & DYNAMICS

ASSIGNMENT SEM 1 2022/2023

DEVELOPMENT OF PIPING & INSTRUMENTATION DIAGRAM (P&ID)

FOR PRODUCTION OF ETHYLENE CARBONATE THROUGH
HETEROGENEOUS CATALYTIC REACTION

LECTURER’S NAME : DR. AAINAA IZYAN BINTI NAFSUN

SECTION : 01
GROUP MEMBERS :

NAME MATRIC NO.

ASHVINITHA UTHAYA KUMAR KA18092

HARSHINI BASKARAN KA19091

DHARSHINI DEVI A/P RAJABALAN KA19041

MUHAMMAD AFIQ IKMAL BIN AFANDI KA20040

 TABLE OF CONTENTS

TITLE PAGE

1. FUNCTION OF EACH UNIT OPERATION 1-2

2. PROCESS DESCRIPTION WITH UNIT OPERATION 3

3. CONFIGURATION OF CONTROL LOOPS

a) Toluene Storage Drum, V-101 4-6
b) Toluene Feed Pumps, P-101 A/B 4-6
c) Feed Preheater, E-101 7-8
d) Feed Heater, H-101 7-8
e) Reactor, R-101 9-10
f) Recycle Gas Compressor, C-101 A/B 9-10
g) Reactor Effluent Cooler, E-102 11-13
h) High Pressure Phase Separator, V-102 11-13
i) Low Pressure Phase Separator, V-103 13-15
j) Tower Feed Heater, E-103 15-16
k) Benzene Reboiler, E-106 17-18
l) Benzene Column, T-101 18-20
m) Benzene Condenser, E-104 20-21
n) Reflux Drum, V-104 22-23
o) Reflux Pumps, P-102 A/B 23-24
p) Product Cooler, E-105 25-26

4. PIPING & INSTRUMENTATION DIAGRAM (P&ID) 27

5. REFERENCES 28
 1. FUNCTION OF EACH UNIT OPERATION
Unit Operation
Toluene Storage Drum, V-101
High Pressure Phase Sep, V-102
Low Pressure Phase Sep, V-103
Reflux Drum, V-104
Toluene Feed Pumps, P-101 A/B
Reflux Pumps, P-102 A/B
Feed Preheater, E-101
Reactor Effluent Cooler,E-102
Tower Feed Heater, E-103
Benzene Condenser, E-104
Function
To mix the fresh toluene with recycled toluene
at 25°C.
To separate the hydrogen, methane vapor at
the top stream and toluene and benzene and a
small fraction of methane and hydrogen in
liquid phase at the bottom stream at 23.9 bar
(stream 8).
To separate the small fraction of methane and
hydrogen at the top stream and toluene and
benzene and in liquid phase at the bottom
stream at 2.9 bar (stream 18).
To remove remaining methane and hydrogen
(stream 14).
To increase the pressure of fresh and recycled
toluene to 25.2 bar.
To Increase the flow rate to 3.3 bar.
To heat the mixture of toluene and hydrogen
to 225°C.
To cool the reactor effluent to 38°C.
To heat the tower feed to 90°C.
To condense the benzene vapor at 112°C.
Product Cooler, E-105 To cool the products to 38°C.

Benzene Reboiler, E-106 To increase the temperature to 112°C and boil

the benzene from the bottom of the distillation
column that generates vapor which returns to
the column.

Feed Heater, H-101 To increase the temperature of mixture to

600°C by using sir to combust fuel gas.

Reactor, R-101 The heated mixture reacts with recycled

hydrogen and is fed to a packed bed catalytic
reactor to produce benzene and methane at
optimum operating conditions at 24.81 bar
and 600°C.

Recycle Gas Compressor, C-101 A/B To compress the methane and hydrogen vapor
to 25.5 bar.

Benzene Column, T-101 To purify benzene by separate toluene which

is then recycled (stream 11) and benzene
which is cooled and collected (stream 13).
 2. PROCESS DESCRIPTION WITH UNIT OPERATION

Process Description Process flow diagram (PFD) for benzene production is shown in Figure 1.
Based on Figure 1, unit operations used in this process include heater and cooler (E-101, E-102,
E-103 and E-105), condenser (E-104), reboiler (E-106), pump (P-101A/B and P102A/B),
compressor (C-101A/B), fired heater (H-101), toluene storage drum (V-101), separator (V-102
and V-103), reflux drum (V-104), reactor (R-101) and benzene column (T-101).

The process started with two raw materials, toluene and hydrogen. The fresh toluene feed (S1)
along with recycle stream (S11) is pressurized and mixed with hydrogen (S3 and S5). The
mixture is fed to a heater (E-101) followed by a furnace heater (H-101) to increase the
temperature to around 600 ºC. The heated stream (S4) along with a small fraction of recycled
hydrogen stream (S7) is introduced into a packed bed catalytic reactor (R-101). The reactor
effluents are cooled and fed to phase separators (V102 and V-103) to separate unreacted
hydrogen along with product methane. A part of the separated gasses is recycled back, and the
rest is collected as fuel gas (S16). The liquid stream (S10) from the second phase separator is fed
to the distillation column after passing through the feed heater (E-103). The distillation column
separates the light key component (benzene) which is subsequently cooled and stored (S15). The
bottom stream consisting of heavy components (toluene) is recycled back to the toluene vessel.
 3. CONFIGURATION OF CONTROL LOOPS FOR EACH UNIT OPERATION

a) Toluene Storage Drum, V-101

b) Toluene Feed Pumps, P-101 A/B

Loop 1

FT: Flow Transmitter

FIC: Flow Indicator Controller

FAH: Flow Alarm High

FAL: Flow Alarm Low

1/P: Transducer
 Control Objective Control the inlet flow rate of toluene
storage drum, V-101

Control Variable Inlet flow rate of V-101

Manipulated variable Inlet flow rate of V-101 via control valve

Disturbance Variable Deviation inlet flow rate of V-103

Type of Control System Feedback control

Loop 2

LT: Level Transmitter

LIC: Level Indicator Controller

LAH: Level Alarm High

LAL: Level Alarm Low

1/P: Transducer

Control Objective Regulate the level of toluene storage

drum. V-101

Control Variable Level of V-101

Manipulated variable Bottom outlet flow rate of V-101 via

toluene feed pumps, P-101 A/B

Disturbance Variable Deviation inlet flow rate of V-101

 Type of Control System Feedback control

Loop 3

FT: Flow Transmitter

FIC: Flow Indicator Controller

FAH: Flow Alarm High

FAL: Flow Alarm Low

1/P: Transducer

Control Objective Control the flow rate of stream 2

Control Variable flow rate of stream 2

Manipulated variable Overhead Inlet flow rate of V-101 via

control valve

Disturbance Variable Deviation in overhead inlet flow rate of

V-101

Type of Control System Feedback control

 c) Feed Preheater, E-101
d) Feed Heater, H-101

Loop 4

TT: Temperature Transmitter

TIC: Temperature Indicator Controller

TAH: Temperature Alarm High

TAL: Temperature Alarm Low

1/P: Transducer

Control Objective Regulate temperature inlet of feed heater

H-101

Control Variable Temperature inlet of H-101

 Manipulated variable flow rate of high pressure stream that enter
heat exchanger E-101

Disturbance Variable Deviation in inlet flow rate of stream that

enter heat exchanger E-101

Type of Control System Feedback control

Loop 5

FT: Flow Transmitter

FIC: Flow Indicator Controller

FAH: Flow Alarm High

FAL: Flow Alarm Low

1/P: Transducer

Control Objective Regulate the flow rate of Air entering feed

heater H-101

Control Variable flow rate of Air entering H-101

Manipulated variable Air flow rate entering feed heater H-101

Disturbance Variable Fuel gas flow rate entering feed heater

H-101

Type of Control System Ratio control

 e) Reactor, R-101
f) Recycle Gas Compressor, C-101 A/B

Loop 6

FT: Flow Transmitter

FIC: Flow Indicator Controller

FAH: Flow Alarm High

FAL: Flow Alarm Low

1/P: Transducer

Control Objective Regulate the flow rate of stream 7

entering reactor R-101
 Control Variable flow rate of stream 7 entering reactor
R-101

Manipulated variable flow rate of stream 7 entering reactor

R-101 via valve

Disturbance Variable flow rate of stream 5

Type of Control System Feedback control

Loop 7

PT: Pressure Transmitter

PIC: Pressure Indicator Controller

PAH: Pressure Alarm High

PAL: Pressure Alarm Low

1/P: Transducer

Control Objective Regulate the pressure of outlet stream

recycle gas separator C-101 A/B

Control Variable pressure of outlet of C-101 A/B

Manipulated variable Pressure of inlet stream entering C-101

A/B

Disturbance Variable Pressure of inlet stream of C-101 A/B

 Type of Control System Feedforward control

g) Reactor Effluent Cooler, E-102

h) High Pressure Phase Separator, V-102

Loop 8

TT: Temperature Transmitter

TIC: Temperature Indicator Controller

TAH: Temperature Alarm High

TAL: Temperature Alarm Low

1/P: Transducer
 Control Objective Regulate temperature inlet of high pressure
phase separator V-102

Control Variable Temperature inlet of V-102

Manipulated variable Flow rate of cooling water stream that

enter heat exchanger E-102

Disturbance Variable Temperature deviation of inlet flow rate of

stream that enter heat exchanger E-102

Type of Control System Feedback control

Loop 9

FT: Flow Transmitter

FIC: Flow Indicator Controller

FAH: Flow Alarm High

FAL: Flow Alarm Low

1/P: Transducer

Control Objective Regulate the flow rate of overhead outlet

stream leaving high pressure phase
separator V-102

Control Variable Flow rate of overhead outlet stream leaving

V-102
Manipulated variable Flow rate of overhead outlet stream leaving
V-102

Disturbance Variable Flow rate of stream that entering recycle

gas separator C-101 A/B

Type of Control System Feedforward control

i) Low Pressure Phase Separator, V-103

 Loop 10

1/P : Transducer

FC : Flow Controller

FT : Flow Transmitter

FAH : Flow Alarm High

FAL : Flow Alarm Low

Control Objective To control the inlet flow rate of the V-103

Type of Control System Feedback

Controlled Variable Inlet flow rate of separator, V-103

Manipulated Variable Inlet flow rate of the stream entering

separator via valve

Disturbance Variable Deviation of inlet flow rate to the

separator, V-103

Loop 11

1/P : Transducer

PC : Pressure Controller

PT : Pressure Transmitter

PAH : Pressure Alarm High

PAL : Pressure Alarm Low

Control Objective To decrease the pressure in stream 18 at

2.9 bar

Type of Control System Feedback

Controlled Variable Pressure of outlet stream 18

Manipulated Variable Outlet flow rate of stream 18 via the valve

Disturbance Variable Inlet flow rate to the V-103

j) Tower Feed Heater, E-103

 Loop 12

1/P : Transducer

TC : Temperature Controller

TT : Temperature Transmitter

TAH : Temperature Alarm High

TAL : Temperature Alarm Low

Control Objective To heat the feed temperature entering the

column

Type of Control System Feedback

Controlled Variable Temperature of stream 10

Manipulated Variable Inlet flow rate of low-pressure steam

entering the heater

Disturbance Variable Inlet flow rate of stream 18

 k) Benzene Rebolier, E-106

Loop 13

1/P : Transducer

TC : Temperature Controller

TT : Temperature Transmitter

TAH : Temperature Alarm High

TAL : Temperature Alarm Low

Control Objective To increase the temperature at 112℃ to

boil the benzene
Type of Control System Feedback

Controlled Variable Temperature of the reboiler stream back to

the column

Manipulated Variable Inlet flow rate of medium-pressure steam

entering the heater

Disturbance Variable Outlet flow rate of bottom stream

l) Benzene Column, T-101

 Loop 14

1/P : Transducer

FC : Flow Controller

FT : Flow Transmitter

FAH : Flow Alarm High

FAL : Flow Alarm Low

Control Objective To control the inlet flow rate of stream 10

Type of Control System Feedback

Controlled Variable Inlet flow rate of stream 10

Manipulated Variable Inlet flow rate of stream 10 via valve

Disturbance Variable Deviation of inlet flow rate at stream 10

Loop 15

1/P : Transducer

FC : Flow Controller

FT : Flow Transmitter

FAH : Flow Alarm High

FAL : Flow Alarm Low

Control Objective To control the outlet flow rate of stream 13

Type of Control System Feedback

Controlled Variable Outlet flow rate of stream 13

Manipulated Variable Outlet flow rate of stream 13 via valve

Disturbance Variable Deviation of outlet flow rate at stream 13

m) Benzene Condenser, E-104

 Loop 16

1/P : Transducer

TC : Temperature Controller

TT : Temperature Transmitter

TAH : Temperature Alarm High

TAL : Temperature Alarm Low

Control Objective To control the temperature at 112℃ before

entering reflux drum

Type of Control System Feedback

Controlled Variable Temperature of the stream entering reflux

drum

Manipulated Variable Inlet flow rate of cooling water entering the

cooler

Disturbance Variable Temperature of inlet flow rate to the cooler

at stream 13
 n) Reflux Drum, V-104

Loop 17

1/P : Transducer

LC : Level Controller

LT : Level Transmitter

LAH : Level Alarm High

LAL : Level Alarm Low

Control Objective To monitor the level of reactants entering
reflux drum to prevent overflowing

Type of Control System Feedback

Controlled Variable Level of V-104

Manipulated Variable Inlet flow rate of stream entering drum via

valve

Disturbance Variable Deviation of outlet flow rate at stream 19

o) Reflux Pumps, P-102 A/B

 Loop 18

1/P : Transducer

PC : Pressure Controller

PT : Pressure Transmitter

PAH : Pressure Alarm High

PAL : Pressure Alarm Low

Control Objective To control the pressure at stream 14

Type of Control System Feedback

Controlled Variable Pressure of outlet stream 14

Manipulated Variable Outlet flow rate of V-104 entering pump

via the valve

Disturbance Variable Deviation of flow rate entering the pump,

P-102 A/B
 p) Product Cooler. E-105

Loop 19

1/P : Transducer

TC : Temperature Controller

TT : Temperature Transmitter

TAH : Temperature Alarm High

TAL : Temperature Alarm Low

Control Objective To control the temperature at 38℃ before

storing
Type of Control System Feedback

Controlled Variable Temperature of the stream 15

Manipulated Variable Inlet flow rate of cooling water entering the

cooler

Disturbance Variable Temperature of inlet flow rate to the cooler

at stream 14
4. PIPING & INSTRUMENTATION DIAGRAM (P&ID)
 FAH
FAL
1/p TIC
Piping & Instrumentation Diagram (P&ID) 1/p
204 FT FIC Fuel Gas
1 206 206

C-101 A/B
1
16
1/p LAH
Toluene TAH TAH LAL
TAL TAL

61 1/p
FT FIC 21
203 203
E-101 TT TC TT LC LT
H-101 1/p
204 104 104 104 104

FAH 6 FAH
1
19
FAL 14 17 1/p
FAL
1/p
V-101
1/p
FIC LT PT 18 1/p
FC FT
201 202 PIC 207 101 101
Air 207
P-101 A/B FAH
FAH
LAH
117 FAL
FAL R-101
LAL FT
PAH FC FT E-104
205
FT PAL 101 101
201 FT Fuel gas 113
LIC
1/p 205 V-104
202

FIC FAH TAH

1/p 1/p PAH
205 FAL TAL FAH
3 FAL PAL

TIC T-101
208 FT FIC
Hydrogen FC FT PT PC
209 209 E-103
103 103 102 102
1/p 18
1
10 1
12
FAH 1/p
TT
FAL 1/p
208
1
14
TAH
PT TAL
19 103
E-102

PAH TC TT
1/p
PAL 103 103
V-102 V-103

PC
1/p TAH
103
TAL

TC TT
1/p
105 105

E-106 Benzene
E-105
TAH
TAL

TC TC
1/p
103 103
REFERENCES

1. Theoretical investigation of aromatics production enhancement in thermal coupling of

naphtha reforming and hydrodealkylation of toluene. (2011, August 10). Theoretical
Investigation of Aromatics Production Enhancement in Thermal Coupling of Naphtha
Reforming and Hydrodealkylation of Toluene - ScienceDirect.
https://doi.org/10.1016/j.cep.2011.07.011

2. A novel integrated thermally coupled moving bed reactors for naphtha reforming
process with hydrodealkylation of toluene. (2016, October 20). A Novel Integrated
Thermally Coupled Moving Bed Reactors for Naphtha Reforming Process With
Hydrodealkylation of Toluene - ScienceDirect.
https://doi.org/10.1016/j.applthermaleng.2016.10.118

3. Control Loop Performance Monitoring Solution - Control Station. (2021, June 4).
Control Station. https://controlstation.com/control-loop-performance-monitoring/

4. Industrial and Laboratory Reactors – Chemical Reaction Hazards and Process

Integration of Reactors. (2014, December 5). Industrial and Laboratory Reactors –
Chemical Reaction Hazards and Process Integration of Reactors - ScienceDirect.
https://doi.org/10.1016/B978-0-08-094242-1.00021-8