Final Assignment Bkf3413 Sem 2 20192020 (1)

SUBJECT: PROCESS DYNAMICS & CONTROL TOPIC: P&ID

MARKS:

CODE: BKF3413

ASSESSMENT: Assignment P&ID (10%)

NAME: _______________________________

NO: 1

TIME: 3 WEEKS

MATRIC ID: ______________________________

Assignment (10%) Process Control & Dynamic (BKF3413)

Development of Piping & Instrumentation Diagram (P&ID) for Production of Acrylic Acid

Acrylic acid is normally used as a starting material in the synthesis of emulsion and solution polymers. Acrylic emulsion polymers were firstly used as coatings for leather in the early 1930s and its application then widely used as binders of leather, textiles, and papers, as well as exterior coatings in home and industry, adhesives, laminates, elastomers, plasticizer, and floor polishes. The most economical synthesis route for acrylic acid production is based on the two stages vapor phase oxidation of propylene. The propylene oxidation process is attractive because of the availability of highly active and selective catalysts and the relatively low cost of propylene. Figure 1 shows the process flow diagram for acrylic acid production from propylene. The raw materials used for this process are propylene, steam and air. The propylene conversion for this process is 95% and the selectivity is 78%. The main product for the oxidation of propylene is acrylic acid with the purity over 99%, the side products are acetic acid, water vapor and carbon dioxide. The vapor phase oxidation of propylene is conducted using a tubular reactor (R-101). Additional recovery of acrylic acid and acetic acid occurs in an absorber (T-101). The stream leaving the absorption section is a dilute and aqueous acid mixture. It then proceeds to an extraction unit, T-102, which contains an extractor and a solvent recovery tower. Acetic acid and acrylic acid have low volatilities with respect to water and thus vacuum condition would be required to ensure the temperature of concentrated acrylic acid not to be greater than 90°C. For extraction purpose, N-butyl acetate is used as solvent since it is a typical solvent with low solubility in water and high solubility in acrylic acid. Acrylic acid is

SUBJECT: PROCESS DYNAMICS & CONTROL TOPIC: P&ID ASSESSMENT: Assignment P&ID (10%)

NAME: _______________________________

MARKS:

CODE: BKF3413 NO: 1

TIME: 3 WEEKS

MATRIC ID: ______________________________

separated from the large volume of water by solvent extraction (T-104). In last distillation column (T-105), 99.9 mole% acrylic acid is produced as the bottom product, and 95 mole% acetic acid is produced as the top product. The acrylic acid product is cooled before it is transferred to storage tank. However the storage temperature for acrylic acid temperature must be maintained below 90°C in order to avoid spontaneous polymerization. The reactions involved for acrylic acid production are shown below:

Based on Figure 1, the list of unit operations involved for acrylic acid production is shown in Table 1. Meanwhile the operating condition and related data for each streams are given in Tables 2-5.

SUBJECT: PROCESS DYNAMICS & CONTROL TOPIC: P&ID

MARKS:

CODE: BKF3413

ASSESSMENT: Assignment P&ID (10%)

NO: 1

NAME: _______________________________

TIME: 3 WEEKS

MATRIC ID: ______________________________

Table 1 List of unit operations for acrylic acid production No.

Label

Unit Operation

1

C-101

Air compressor

2

C-102

Turbine

3

C-103

Turbine

4

E-101

Reactor feed heater

5

E-102

Reactor product cooler

6

E-103

Cooler

7

E-104

Heater

8

E-105

Cooler

9

E-106

Cooler

10

E-107

Cooler

11

E-108

Cooler

12

P-101

Pump

13

P-102

Recycle pump

14

P-103

Product pump

15

R-101

Reactor

16

S-102

Acrylic acid storage

17

T-101

Absorber column

18

T-102

Extraction column

19

T-103

Distillation column

20

T-104

Solvent recovery column

21

T-105

Purification column

SUBJECT: PROCESS DYNAMICS & CONTROL

ASSESSMENT: Assignment P&ID (10%)

NAME: _______________________________

CODE: BKF3413 NO: 1

TIME: 3 WEEKS

MATRIC ID: ______________________________

Figure 1 Process flow diagram for acrylic acid production

TOPIC: P&ID

MARKS:

MARKS:

SUBJECT: PROCESS DYNAMICS & CONTROL TOPIC: P&ID

CODE: BKF3413

ASSESSMENT: Assignment P&ID (10%)

NO: 1

NAME: _______________________________

TIME: 3 WEEKS

MATRIC ID: ______________________________

Table 2 Data for stream number 1-8 Stream No. From To Temperature Pressure Substream: MIXED Phase: Component Mole Flow Propylene Oxygen Nitrogen Water Carbon Dioxide Acrylic Acid Acetic Acid N-butyl Acetate Total Mole Flow

1

C Bar

kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr

C-101 25 1

2 3 C-101 MIXER MIXER 25 25 5 5

4 MIXER 159 5

5 MIXER E-101 102.12 5

6 E-101 R-101 310 4.3

7 R-101 E-102 310 3.39

8 E-102 C-102 160 3.39

Vapor

Vapor

Vapor

Vapor

Mixed

Vapor

Vapor

Vapor

0 531.26 1998.54 0 0 0 0 0 2529.8

0 531.26 1998.54 0 0 0 0 0 2529.8

240.38 0 0 0 0 0 0 0 240.38

0 0 0 901.44 0 0 0 0 901.44

240.38 531.26 1998.54 901.44 0 0 0 0 3671.62

240.38 531.26 1998.54 901.44 0 0 0 0 3671.62

12.02 66.61 1998.54 1202.4 122.11 178.84 13.22 0 3593.74

12.02 66.61 1998.54 1202.4 122.11 178.84 13.22 0 3593.74

MARKS:

SUBJECT: PROCESS DYNAMICS & CONTROL TOPIC: P&ID ASSESSMENT: Assignment P&ID (10%)

CODE: BKF3413 NO: 1

NAME: _______________________________

TIME: 3 WEEKS

MATRIC ID: ______________________________

Table 3 Data for stream number 9-16 Stream No. From To Temperature Pressure Substream: MIXED Phase: Component Mole Flow Propylene Oxygen Nitrogen Water Carbon Dioxide Acrylic Acid Acetic Acid N-butyl Acetate Total Mole Flow

C Bar

kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr

9 C-102 T-101 91.47 1.2

10 T-101 75 0.84

Vapor 12.02 66.61 1998.54 1202.4 122.11 178.84 13.22 0 3593.74

11 T-101 68.76 0.8

12 T-101 E-103 81.15 1.16

13 E-103 T-102 50 1.2

Liquid

Vapor

Liquid

0 0 0 503.31 0 0 0 0 503.31

12.01 66.58 1998 1264.38 121.99 20.7 0.38 0 3484.04

0.01 0.02 0.54 441.32 0.13 158.15 12.84 0 613.01

14

16 T-102

T-102 50 1.2

15 T-102 E-104 56.52 1.2

Liquid

Liquid

Liquid

Liquid

0.01 0.02 0.54 441.32 0.13 158.15 12.84 0 613.01

0 0 0 0 0 0 0 1371.08 1371.08

0.01 0.02 0.54 161.43 0.13 158.15 12.84 1370.94 1704.05

0 0 0 279.9 0 0 0 0.14 280.04

47.96 1.2

MARKS:

SUBJECT: PROCESS DYNAMICS & CONTROL TOPIC: P&ID ASSESSMENT: Assignment P&ID (10%)

CODE: BKF3413 NO: 1

NAME: _______________________________

TIME: 3 WEEKS

MATRIC ID: ______________________________

Table 4 Data for stream number 17-24 Stream No. From To Temperature Pressure Substream: MIXED Phase: Component Mole Flow Propylene Oxygen Nitrogen Water Carbon Dioxide Acrylic Acid Acetic Acid N-butyl Acetate Total Mole Flow

C Bar

kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr

17 E-104 T-103 125 1.02

18 T-103 E-105 56.43 0.14

19 T-103 E-106 146.46 1.8

20 E-105 P-101 35 0.14

21 P-101 35.08 1

22 E-106 C-103 139 1.8

23 C-103 T-104 138.99 1.39

24 T-104 E-107 124.48 0.97

Vapor

Vapor

Liquid

Liquid

Liquid

Liquid

Liquid

Vapor

0.01 0.02 0.54 161.43 0.13 158.15 12.84 1370.94 1704.05

0.01 0.02 0.54 160.84 0.13 0 0 0.01 161.54

0 0 0 0.59 0 158.15 12.84 1370.93 1542.5

0.01 0.02 0.54 160.84 0.13 0 0 0.01 161.54

0.01 0.02 0.54 160.84 0.13 0 0 0.01 161.54

0 0 0 0.59 0 158.15 12.84 1370.93 1542.5

0 0 0 0.59 0 158.15 12.84 1370.93 1542.5

0 0 0 0.59 0 3.16 12.82 1337.74 1354.32

MARKS:

SUBJECT: PROCESS DYNAMICS & CONTROL TOPIC: P&ID ASSESSMENT: Assignment P&ID (10%)

CODE: BKF3413 NO: 1

NAME: _______________________________

TIME: 3 WEEKS

MATRIC ID: ______________________________

Table 5 Data for stream number 25-32 Stream No. From To Temperature Pressure Substream: MIXED Phase: Component Mole Flow Propylene Oxygen Nitrogen Water Carbon Dioxide Acrylic Acid Acetic Acid N-butyl Acetate Total Mole Flow

C Bar

kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr kmol/hr

25 E-107 P-102 50 0.97

26 P-102

28 T-105 E-108 126.72 0.97

29 T-105 E-109 171.36 2.5

30 E-108 P-103 40 0.95

31 P-103

32 E-109

50.02 1.2

27 T-104 T-105 153.5 1.58

40.01 1

50 2.3

Liquid

Liquid

Liquid

Vapor

Liquid

Liquid

Liquid

Liquid

0 0 0 0.59 0 3.16 12.82 1337.74 1354.32

0 0 0 0.59 0 3.16 12.82 1337.74 1354.32

0 0 0 0 0 154.98 0.02 33.18 188.19

0 0 0 0 0 1.61 0.02 13.61 15.24

0 0 0 0 0 153.37 0 19.57 172.94

0 0 0 0 0 1.61 0.02 13.61 15.24

0 0 0 0 0 1.61 0.02 13.61 15.24

0 0 0 0 0 153.37 0 19.57 172.94

SUBJECT: PROCESS DYNAMICS & CONTROL TOPIC: P&ID ASSESSMENT: Assignment P&ID (10%)

NAME: _______________________________

MARKS:

CODE: BKF3413 NO: 1

TIME: 3 WEEKS

MATRIC ID: ______________________________

Tasks: This is a group assignment. One group may consist of 3-5 members.

a)

Describe the functions of each unit operation involved as listed in Table 1.

b)

Based on stream data for acrylic acid production as shown in Tables 2-5, develop and draw configuration control loops for all unit operations involved. Each unit operation must have at least one configuration control loop. Each control loop must include the controller objective, types of controller (feedback, feedforward, ratio control etc.), controlled variable and manipulated variables.

c)

Based on b), draw a detailed Piping & Instrumentation Diagram (P&ID) for this process by including all the control loops and instrumentation (transmitter, transducer and alarm) in A3 sheet. The drawing should be done using Microsoft Visio.

d)

All of the given tasks need to be compiled in one report. The report must be type using Microsoft Word. The structure of the report consists of main page (names, section and ID), table of content, process description with operating conditions, control loop for each unit operations (explain one by one for each unit operations), P&ID diagram in A3 and references. The submission deadline is 6 March 2020 before 5.00 p.m. Please submit your assignment report according to your section.