EH2208O

DESIGN PROJECT II (MARCH 2017)

PRODUCTION OF 20,000 METRIC TONNES OF

POLYTETRAFLUOROETHYLENE PER YEAR

CHAPTER 4: PROCESS CONTROL &

INSTRUMENTATIONS

GROUP MEMBERS

AIMAN HAKIM BIN ROSLAN 2013849224

FATIN FATIHA BINTI ABDUL RAHIM 2014850038
HANEARYTHA LITAD CHARLES 2014679702
MUHAMMAD FAHMI BIN NIZAM 2013251462
NOOR AMILIA BINTI KHOSIM 2014231358
NURBADAYU BINTI BASIRON 2013493592

SUPERVISOR:
MS CHRISTINA VARGIS

FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA
SHAH ALAM
 CHAPTER 4

PROCESS CONTROL AND INSTRUMENTATION

4.1 PROCESS DESCRIPTION OF PTFE PLANT

The raw material used for the production of PTFE is chlorodifluoromethane (CHClF 2).
The material is stored within a pressurized vessel at 15 bar and 25C to maintain it in
liquid phase as this allows for easier storage and transportation. Upon exiting the tank,
the pressure of CHClF2 is reduced to 12 bar using a valve to prevent damage to the
upcoming equipment due to sudden inflow of high pressure liquid.

The stream is then heated to 450C as a preparatory step before entering a

tubular reactor (Ebnesajjad, 2013). Within the reactor, gaseous CHClF 2 undergoes
pyrolysis reaction and is converted to TFE (C2F4) alongside hydrochloric acid (HCl) as
the side product. When operating at 810C and 6.55 bar, a conversion of 100% can
be achieved as stated by (Ebnesajjad, 2016). The product stream containing TFE and
HCl is then condensed to liquid state before entering a distillation column for
purification and separation. Since HCl has a lower boiling point than TFE, it will exit
through the overhead stream meanwhile TFE exits through the bottom stream. The
separation produces product streams containing 99.9% w/w HCl and 99.5% w/w TFE,
respectively.

The purified HCl is then diluted with water and sold as a second source of revenue.
Meanwhile, the purified TFE is fed to a continuous stirred tank reactor (CSTR) for
polymerization reaction and produce PTFE. Additionally, water and benzoyl peroxide
are added to the reaction which acts as the solvent and organic initiator, respectively
(Ebnesajjad, 2013). According to (Mori, Tsuchiya, & Okahata, 2005), the conversion
can achieve as high as 80% and produce PTFE ranging between 10,000 g/mol to
1,000,000 g/mol.

483
 The product stream is then fed to a mixing tank whereby a surfactant, sodium
borate is added to reduce the interfacial tension and form a stable colloidal dispersion
of PTFE. (Fernandez & Jebbanema, 2007). The sludge-like stream is subsequently
transported using an extruder to a filter press to remove unwanted components (waste
stream) from PTFE.

The discharged waste stream containing unreacted TFE, HCl and water is
purified using two distillation columns whereby TFE and HCl are recycled back into
the process meanwhile water is sent to a water treatment facility. The solid PTFE is
then transferred onto a conveyer belt and dried to remove residual moisture and
achieve the desired 99% purity.

484
4.2 PROCESS FLOW DIAGRAM BEFORE HEAT INTEGRATION

Figure 4.1: Process flow diagram for production of PTFE before heat integration

485
4.3 PROCESS FLOW DIAGRAM AFTER HEAT INTEGRATION

Figure 4.2: Process flow diagram for production of PTFE after heat integration

486
4.4 INTRODUCTION

In todays competitive market, many manufacturing industries are seeking ways to

optimize process performance and improve product quality in order to maintain a
successful operation. For this, engineering process control is often employed as it is
able to maintain the process variables such as temperature, pressure, flow, level and
composition within the desired range. These parameters are important to be controlled
as they would affect not only the product outcome but also the safety and operation of
the plant.

The term process can be defined as the conversion of feed material to

products using chemical and physical operation. On the other hand, process control
relates to the method of controlling certain variables in order to meet the product
specification. The primary objective of process control is to maintain a process at the
desired operating conditions, safely and efficiently, while satisfying environmental and
product quality requirements.

For this PTFE plant, several control strategies are used such as feedback,
feedback-feedforward, cascade, and a few others. Each equipment operate at
different operating conditions and involve different components. Hence, it is crucial to
choose the controlled and manipulated variables carefully to ensure that the
equipment would operate smoothly and efficiently. The major equipment that will be
discussed in this topic are pyrolysis reactor, heat exchanger, condenser, distillation
column and continuous stirred tank reactor (CSTR). Meanwhile minor equipment
include mixing tank, vessel and pump.

487
4.5 COMPONENTS OF CONTROL SYSTEM

As mentioned earlier, the basic components to a control system are measure,

decide and action. Sensors and transmitters are used to measure the controlled
variable such as the temperature, flow, level, etc. and transmit the information in the
form of a signal to a controller. A controller is a device which calculates and decides
the most suitable action that should be taken by control valves in order to maintain the
parameter at the desired set point. Control valves function by reducing or increasing
its opening size corresponding to the information conveyed by the controller.

Table 4.1: Basic components of control system

Instrument Task
Sensor Detect process variables
Example:
Flow orifice, venture, rotameter, turbine
Temperature thermocouple, resistant
temperature detector (RTD), thermometer
Pressure bourdon tube, bellows, diaphragm
sensor
Level air bubble sensor
Transmitter Converts measurement from sensor into signal and
conveys the information to controller
Controller Compares the signal received from transmitter and
the desired set point.
Conveys the output to the control valve in order to
maintain the process variable
Control valve Generally used to control flow by increasing or
decreasing the size of opening.

488
4.6 PROCEDURE FOR IMPLEMENTING CONTROL SYSTEM

Identify the control objective: the central element in any control configuration is the
parameter that needs to be controlled

Variable selection: Determine the parameter to be adjusted (manipulated) which will

directly lead to the desired specification

Select the type of control strategies such as feedback, feedforward, cascade, etc.
according to the suitability of the process

Design the control system and identify further parameters to be controlled

4.7 TYPES OF CONTROL STRATEGIES

4.7.1 Feedback Control

Figure 4.3: Block diagram of feedback control

Source: (Rao, 2009)

489
Feedback system is a type of closed loop control whereby a controller is actively
making adjustments to the process variable to ensure the output remains at the
desired set point. One of the advantages of using feedback system is its simple design
as well as easiness to tune for linear, fast and short dead time processes. The term
feedback was derived from the condition whereby the controlled variable is
measured and fed back to the controller. Here, the output value is compared against
the input whereby any difference (error) between the two will be compensated by
adjusting the manipulated variable (Smith & Corripio, 2006). However, it carries
several disadvantages such that any corrective action may only occur once the
process undergoes a deviation. This might affect the process in several areas such as
material loss, long recovery period as well as product defects.

4.7.2 Feedforward Control

Figure 4.4: Block Diagram of feedforward control

Feedforward is one of the most commonly used control strategy in the process
industries. Its main objective is to measure the disturbance and compensate them
before the controlled variables deviate from the set point (Smith & Corripio, 2006).
Among the advantages of using feedforward control is that it is suitable for slow
process and the disturbance is minimized before it affects the process variable.
However, it carries several drawbacks such that it cannot cope with unmeasured
disturbances, sensitive to variations in process variable and requires a good
knowledge for design and implementation.

490
4.7.3 Feedback-Feedforward

Figure 4.5: Block diagram of feedback-feedforward control

Source: (Perry & Green, 2008)

As the name implies, feedback-feedforward is the combination of feedback and

feedforward control system. This control strategy operates by simultaneously
compensating the effect of disturbance and adjusting the inlet based on the outlet
condition in order to achieve the desired specification. This is a comprehensive control
strategy and is usually used in processes where variations are required to be kept at
a minimum. Some of the advantages of using feedback-feedforward is that the effect
of disturbance is minimized greatly and the product often remains at the desired set
point.

4.7.4 Cascade Control

Figure 4.6: Block diagram of cascade control

Source: ("An Implementation Recipe for Cascade Control," 2015)

491
Cascade system comprises of two control loops, known as the inner (secondary) and
outer (primary). The primary loops produces the set point and conveys the information
to the inner loop, which performs adjustment to the process variable. For example, the
control of level within a vessel is the undertaken by a level controller which provides
set point to the flow controller to maintain the level of liquid within the equipment. The
advantages of using this control strategy is that is easy to operate and has faster
recovery time as compared to feedback control. However, the drawback for this
method is that the control would be worst if the controllers are not properly tuned.

4.7.5 Ratio Control

Figure 4.7: Example of ratio control

Another type of control technique that is commonly used is ratio control. It is used
when one variable is manipulated to keep it as a ratio to another. The stream which
cannot be controlled, but only measured is known as the wild flow (Smith & Corripio,
2006). It is usually multipled/divided by a constant where the resulting value is used a
set point for the manipulated variable. The advantage of using this technique is that it
allows two flows to be in proportion to one another and does not require complex
model. However, the disadvantages of using this method is that if one of the flowrate
is not measured directly, the controller assumes that the flows have the correct ratio.
Ratio control is typically used in situations such as:

492
 To maintain a ratio of feed flow rate and the stream at the reboiler of a distillation
column.
Maintaining the stoichiometric ratio of reactants to a reactor.
Maintaining the reflux ratio in a distillation column
Maintaining the ratio of fuel and air to a furnace.
Hold the ratio of two-blended streams, in order to maintain the composition of the
blending.

4.7.6 Selective and Override Control

Figure 4.8: Example of override and selective control

Selective and override control are both a type of control strategy that focuses on the
productivity and safety of the equipment. It operates by selecting the control system
where the process variable exceeds/falls below the limit and ensures the parameter
falls within the specified limit.

493
4.8 DESIGN OF CONTROL SYSTEM FOR MAJOR EQUIPMENT

4.8.1 Pyrolysis Reactor (R-101)

A tubular reactor is used to convert chlorodifluoromethane into TFE and HCl at

operating conditions of 810C and 6.55 bar. At these operating conditions, 100%
conversion of chlorodifluoromethane can be achieved (Ebnesajjad, 2016). There are
also additional advantages when operating at this temperature whereby the
conversion of chlorodifluoromethane and TFE yield can be maximized at the same
time minimizing the amount of by-products formed (Ebnesajjad, 2013).

Selective control is chosen as the control strategy since the temperature within
a tubular reactor varies from one region to another. Whenever the temperature
exceeds 810C, a high selector (HS) will transmit a signal to the controller which in
turn, sends a signal to the heating coil and decreases the temperature within the
reactor. This is to prevent equipment failure as well as material deterioration due to
extreme high temperature.

Additionally, the pressure reactor is maintained by using feedback control

whereby the flowrate of gaseous product is manipulated to ensure the pressure within
the reactor remains at the desired set point.

494
 Piping & Instrumentation Diagram

Symbols
PT Pressure transmitter Equipment: Pyrolysis Reactor (R-
PC Pressure controller 101)
TT Temperature transmitter
TC Temperature controller Date: 30th April 2017
HS Hihg selector
Figure 4.9: P&ID for R-101

495
 Table 4.2: Control system for R-101
No. Objective Controlled Manipulated Disturbance Type of Description Set Point
Variable Variable Control
Strategy
1. To maintain Temperature Heating coil Temperature Selective High selector detects 850C
temperature of reactor of feed the highest
inside R-101 temperature within R-
101 and sends a
signal to the heating
coil to decrease the
temperature
2. To maintain the Pressure of Flowrate of Pressure of Feedback Pressure controller 6.55 bar
pressure inside reactor product feed sends a set point to
reactor outlet (gas) the flow controller in
order to maintain the
pressure of R-101 at
desired set point

496
4.8.2 Cooler (E-101, E-102 and E-103)

A series of cooler is used to reduce the temperature of product exiting R-101 from
850C to 30C. The cooling process is carried out using water at room temperature as
the coolant.

Cascade control is used to maintain the temperature of the process stream

outlet by manipulating the flowrate of cooling water. For this, the process stream outlet
acts as the master/outer loop meanwhile the cooling water acts as the slave/inner
loop. The temperature from the process stream outlet is detected by a temperature
controller which then sends a set point to the flow controller to either increase or
decrease the flowrate of cooling water.

497
 Piping & Instrumentation Diagram

Symbols
FT Flow transmitter Equipment:
FC Flow controller Cooler (E-101, E-102 and E-103)
TT Temperature transmitter
TC Temperature controller Date: 30th April 2017
Figure 4.10: P&ID for E-101, E-102 and E-103

498
 Table 4.3: Control system for E-101, E-102 and E-103
No. Objective Controlled Manipulated Disturbance Type of Description Set Point
Variable Variable Control
Strategy
1. To maintain Temperature Flowrate of Temperature Cascade Temperature E-101 =
temperature of of process cooling water of feed controller sends a 400C
process stream stream outlet set point to the flow E-102 =
outlet and and flowrate controller, which 180C
flowrate of of cooling adjusts the flow of E-103 =
cooling water water cooling water 30C

499
4.8.3 Condenser (E-104)

A condenser is used to condense the gaseous mixture of Stream 6 into liquid phase
at temperature of -41.68C. The coolant used for this process is ethane as it has a
boiling point of -89C and will be able to absorb the heat from the entering fluid.

The control strategy used for this equipment is feedback-feedforward whereby the
temperature of the process outlet is controlled by manipulating the flow of refrigerant
through feedback system, meanwhile the disturbance from feed inlet is compensated
using feedforward system. This provides a comprehensive control and ensures the
outlet temperature remains at the desired set point.

500
 Piping & Instrumentation Diagram

Symbols
FT Flow transmitter Equipment: Cooler (E-104)
FC Flow controller
TT Temperature transmitter
TC Temperature controller Date: 30th April 2017
Figure 4.11: P&ID for E-102

501
 Table 4.4: Control system for E-104
No. Objective Controlled Manipulated Disturbance Type of Description Set Point
Variable Variable Control
Strategy
1. To maintain Temperature Flowrate of Temperature Feedback- Feedback control -41.68C
temperature of of process cooling water of feed inlet Feedforward manipulates the
Stream 7 outlet flowrate of cooling
water, meanwhile
feedforward
control minimizes
the effect of
temperature
fluctuation caused
by the feed inlet

502
4.8.4 Distillation Column (T-101, T-102, T-103)

A distillation column is used to separate a mixture of varying components into its

respective constituents based on the difference of boiling points. For this process,
three distillation columns are used to separate a mixture containing TFE, HCl and
water. T-101 and T-103 are similar whereby the feed component contains a binary
mixture of TFE and HCl. On the other hand, T-102 has an additional component in the
feed stream which is water. For all of these, the control strategy are identical to one
another as the parameters to be controlled are the same.

The most important criteria for a distillation column to maintain the specified
composition at the top and bottom products (Sinnot, 2005). For the top section,
feedback control is used whereby the concentration of distillate is controlled by
manipulating the reflux (stream re-entering the column). This is because the
concentration of distillate is based on the rate of reflux. Whenever the concentration
falls below the specified target, the control valve will open to allow more reflux to enter
the column and consequently increase the concentration of distillate. At the bottom
section, a cascade control system is employed whereby the concentration of bottom
product acts as the master/outer loop and temperature at the bottom section acts as
the slave/inner loop. With this, a set point is transmitted from the concentration
controller to the temperature controller, which then adjusts the rate of steam inlet to
ensure all of the light components are evaporated towards to the top section.

Also, the temperature and pressure of the distillation column is maintained by

using cascade control. For this, the temperature acts as the master meanwhile
pressure acts as the slave. Whenever the pressure exceeds the set point, a signal is
sent from the pressure controller to the temperature controller which adjusts the rate
of cooling water at the condenser. This allows for both temperature and pressure to
be maintained simultaneously.

At the reflux drum, cascade control is used to maintain the level within the
vessel. Here, level within the reflux drum acts as the master meanwhile flowrate of
distillate acts as the slave. Whenever the level falls below the specified limit, a signal
will be sent from the level controller to the flow controller which then decrease the
output of the pump.

503
 Piping & Instrumentation Diagram

Symbols
FT Flow transmitter Equipment: Distillation Column
FC Flow controller (T-101, T-102, T-103)
TT Temperature transmitter
TC Temperature controller
LT Level transmitter Date: 30th April 2017
LC Level controller
Figure 4.12: P&ID for T-101, T-102, T-103

504
 Table 4.5: Control system for T-101, T-102, T-103
No. Objective Controlled Manipulated Disturbance Type of Description Set Point
Variable Variable Control
Strategy
1. To maintain Concentration Reflux Composition Feedback The flow of reflux T-101:
concentration of distillate stream of feed fed back into the HCl = 99.9 wt%
of distillate column is TFE = 0.1 wt%
continuously T-102:
adjusted to ensure HCl = 97.5 wt%
the concentration of TFE = 2.5 wt%
distillate remains at T-103:
the desired set point HCl = 99.9 wt%
TFE = 0.1 wt%
2. To maintain Pressure of T- Flowrate of Pressure of Cascade Pressure controller T-101 = 400 to
pressure of 101 and refrigerant condensate sends a set point to 500 kPa
T-101 and flowrate of temperature T-102 = 450 to
flowrate of refrigerant controller, which 550 kPa
refrigerant adjust the rate of T-103 = 350 to
refrigerant entering 400 kPa
the condenser

505
3. To maintain Level of liquid Flowrate of Flowrate of Cascade Level controller Not less than
level of liquid in reflux drum reflux distillate sends a set point to of the height of
inside reflux and flowrate the flow controller, reflux drum
drum and of distillate which adjusts the
flowrate of power output of the
distillate pump

4. To maintain Composition Flowrate of Composition Cascade A concentration T-101:

composition of bottom distillate of feed controller sends a HCl = 0.5 wt%
of bottom product and set point to the TFE = 99.5 wt%
product and flowrate of temperature T-102:
flowrate of steam controller, which HCl = 2.0 wt%
steam manipulates the rate TFE = 98.0
of steam inlet wt%
entering the reboiler T-103:
HCl = 0.5 wt%
TFE = 99.5 wt%

506
4.8.5 Polymerization Reactor (R-102)

A horizontal CSTR is used to polymerize the monomer, TFE into the polymer, PTFE
at 29 bar and 50C. Water and benzoyl peroxide are added to the reactor which acts
as solvent and organic initiator. The reaction occur in this tank is exothermic reaction.

The flowrate of water inlet is maintained by using feedback control whereby a

signal is transmitted from the flow controller to the pump. This adjusts the power output
of the pump according to maintain the flowrate at 200 kg/h.

A feedback control is used to maintain the level within the reactor. The flowrate
of liquid outlet is manipulated to make sure the level of liquid in the reactor does not
fall below the tank limit.

A cascade control is employed to control the pressure and temperature within

the reactor. For this, the pressure is referred as the master meanwhile temperature
is referred as the slave. Whenever the pressure exceeds the set point, a signal will
be sent from the pressure controller to the temperature controller, which adjusts the
flow of cooling water supplied to the jacket.

507
 Piping & Instrumentation Diagram

Symbols
FT Flow transmitter Equipment: Polymerization Reactor
FC Flow controller (R-102)
LT Level transmitter
LC Level controller
TT Temperature transmitter Date: 30th April 2017
TC Temperature controller
PT Pressure transmitter
PC Pressure controller
Figure 4.13: P&ID for R-102

508
 Table 4.6: Control system for R-102
No Control Objective Controlled Manipulated Disturbance Description Type of Set
Variable Variable Control Point
1 To maintain Flowrate of Flowrate of Flowrate of Flow controller sends a Feedback 200 kg/h
flowrate of H2O H2O inlet H2O inlet Stream 19 signal to adjust the
inlet flowrate of H2O inlet
entering R-102
2 To maintain level of Level of Flowrate of Flowrate of Level controller sends a Feedback Not less
liquid in R-102 liquid in R- Stream 19 feed signal to adjust the Control than
102 flowrate of product of height
leaving R-102
3 To maintain Temperature Flowrate of Temperature Pressure controller Cascade T= 50
pressure and and cooling of feed sends a signal to the P = 29
temperature in pressure in water temperature controller, bar
R-102 R-102 which adjusts the flow of
cooling water entering
the jacket

509
4.9 DESIGN OF CONTROL SYSTEM FOR MINOR EQUIPMENT

4.9.1 Pump (P-101, P-102, P-103, P-104, P-105, P-106)

A centrifugal pump is used to pump liquid before entering the subsequent equipment.
The main purpose of this equipment is to increase the pressure of the liquid and ensure
a continuous flow throughout the process.

The chosen control strategy for this pump is feedback control strategy. Any
fluctuations in pressure will be adjusted by flow controller by adjusting the power of
the pump. Whenever the flowrate falls below the specified target, a signal will be sent
to the pump to increase the power output and allow the liquid to flow towards the
proceeding equipment.

Piping & Instrumentation Diagram

Equipment: Centrifugal Pump

Symbols (P-101, P-102, P-103, P-104, P-
FT Flow transmitter 105,
FC Flow controller P-106)

Date: 30th April 2017

Figure 4.14: P&ID for P-101, P-102, P-103, P-104, P-105, P-106

510
 Table 4.7: Control system for P-101, P-102, P-103, P-104, P-105, P-106
No. Objective Controlled Manipulated Disturbance Type of Description Set Point
Variable Variable Control
Strategy
1. To maintain the Flowrate of Power of Flowrate of Feedback A signal is sent P-101 = 1050 kPa
flowrate of outlet pump feed inlet Control from the flow P-102 = 1050 kPa
outlet controller to P-103 = 2950 kPa
adjust the power P-104 = 2950 kPa
output and P-105 = 1050 kPa
ensure the outlet P-106 = 2950 kPa
flows
continuously

511
4.9.2 Dilution Tank (V-101)

A vessel is used to dilute Stream 14 containing 99.5% w/w HCl to 35% w/w. The
product is then sold as a second source of revenue. Additionally, a recycle stream
containing the same purity as the process stream is fed to the vessel. The
concentration of 35% w/ HCl is chosen based on the common concentration of HCl
sold in market.

The temperature inside the vessel is maintained using feedback control by

manipulating the flowrate of steam. A temperature controller will ensure prevent icing
does not occur from the contact between water in Stream 13 and components from
Stream 14 at low temperature.

A feedback control is used to maintain the level within the vessel. The flowrate
of liquid outlet is manipulated to make sure the level of liquid in the vessel does not
decrease below the tank limit.

Ratio control is used to ensure the flowrate of Stream 28 is in proportion to

Stream 13 before entering the vessel. For this, Stream 28 is referred to as the wild
flow and provides the set point for the flow controller, which adjusts the flowrate of
Stream 13. This ensures that the amount of liquid entering the vessel is at the desired
specification.

512
 Piping & Instrumentation Diagram

Symbols
FT Flow transmitter Equipment: Vessel (V-101)
FC Flow controller
TT Temperature transmitter
TC Temperature controller
LT Level transmitter Date: 30th April 2017
LC Level controller
Figure 4.15: P&ID for V-101

513
 Table 4.8: Control system for V-101
No Control Controlled Manipulated Disturbance Description Type of Set Point
Objective Variable Variable Control
1 To maintain Temperature Flowrate of Temperature A flow Feedback 9C
the inside vessel steam into of Stream 14 controller Control
temperature heating jacket sends a signal
inside vessel to adjust the
flow of steam
2 To maintain Level of liquid in Flowrate of liquid Flowrate of Level Feedback Not less than
the level of vessel HCl Stream 14 controller Control of the
liquid in vessel sends a signal vessel height
to adjust the
flowrate of HCl
outlet
4 To maintain Flowrate of Flowrate of Flowrate of A multiplier is Ratio Stream 13:
the flowrate Stream 13 and Stream 13 HCl outlet used to Stream 38
between Stream 38 maintain the =
Stream 13 and flowrate of 3214 kg/h:
38 Stream 13 and 12 kg/h
38 to ensure
the amount of
liquid is
according to
specification

514
4.9.3 Mixer (MIX-101)

A mixer is used to mix Stream 15 containing purified TFE from T-101 with Recycled
Stream 29 containing TFE from T-103.

Ratio control is used to maintain the flowrate of Stream 29 and Stream 13 so

that they are in proportion to one another. Stream 29 is referred to as the wild flow
and provides the set point for the flow controller, which adjusts the flowrate of Stream
15. This ensures that the amount of liquid entering the vessel is at the desired
specification.

A cascade control is used to maintain the level within the vessel by sending a
set point to a flow controller, which adjusts the power output of the pump.

Piping & Instrumentation Diagram

Symbols
AT Concentration transmitter Equipment: Mixer (MIX-101)
AC Concentration controller
LT Level transmitter
LC Level controller Date: 30th April 2017
Figure 4.16: P&ID for MIX-10

515
 Table 4.9: Control system for V-101
No Control Objective Controlled Manipulated Disturbance Description Type of Set Point
Variable Variable Control
1 To maintain flowrate Flowrate of Flowrate of Flowrate of A multiplier is used Ratio Stream 15:
of Stream 15 and Stream 15 Stream 13 Stream 18 to maintain the Control Stream 29
Stream 29 and Stream flowrate of Stream =
29 13 and 38 to ensure 2386 kg/h:
the amount of liquid 573 kg/h
is according to
specification
2 To maintain the level Level of Power Flowrate of Level controller Cascade Not less
inside vessel and liquid inside output of feed sends a signal to the than of
flowrate of Stream vessel and pump flow controller, vessel
18 flowrate of which adjusts the height
Stream 18 power output of the
pump

516
4.9.4 Mixing Tank (V-102)

A vessel is used to agglomerate the PTFE exiting from R-101 with the sodium borate
to produce solid PTFE.

The flowrate of sodium borate and mixture inlet is controlled using cascade
control by manipulating the flowrate of sodium borate inlet. The flowrate of sodium
borate inlet acts as the master, meanwhile the Stream 19 acts as the slave.

Piping & Instrumentation Diagram

Symbols
FT Flow transmitter Equipment: Vessel (V-102)
FC Flow controller

Date: 30th April 2017

Figure 4.17: P&ID for V-102

517
 Table 4.10: Control system for V-102
No Control Controlled Manipulated Disturbance Description Type of Set Point
Objective Variable Variable Control
1 To maintain the Flowrate of Flowrate of Flowrate of By adjusting Cascade 3163 kg/h
flowrate of sodium borate sodium borate outlet V-102 the flowrate
sodium borate and mixture inlet of sodium
and Stream 19 inlet borate inlet

518
4.9.5 Dryer (D-101)

The final separation process occurs within a drying unit whereby hot air at 55C is
used to remove residual water in the PTFE solid. A tray dryer is used as it is suitable
for products such as crude drugs, chemicals, powders or granules.

The temperature within the dryer and flowrate of dry air is maintained by using
cascade control. For this, the temperature is referred as the master meanwhile the
flowrate of dry air is referred as the slave. Whenever the temperature within dryer
falls below the set point, a signal will be sent from the temperature controller to the
flow controller, which adjusts the flowrate of dry air entering the dryer.

Piping & Instrumentation Diagram

Symbols
FT Flow transmitter Equipment: Dryer (D-101)
FC Flow controller
TT Temperature transmitter
TC Temperature controller
Date: 30th April 2017
Figure 4.18: P&ID for D-10

519
 Table 4.11: Control system for D-101
No Control Controlled Manipulated Disturbance Description Type of Set Point
Objective Variable Variable Control
1 To maintain the Temperature of Flowrate of Temperature A temperature Cascade 55C
temperature of dryer and dry air of Stream 29 controller sends a
dryer and flowrate of dry signal to the flow
flowrate of dry air controller, which
air adjusts the
flowrate of dry air
entering the dryer.

520
4.10 OVERALL PIPING & INSTRUMENTATION DIAGRAM (P&ID)

Figure 4.19: Overall P&ID for production of PTFE

521
REFERENCES

1. Ebnesajjad, S. (2013). Introduction to Fluoropolymers: Materials, Tehcnology,

and Applications (1st Edition ed.): Elsevier Science & Technology Books.
2. Ebnesajjad, S. (2016). Expanded PTFE Applications Handbook: Technology,
Manufacturing and Applications. Cambridge: Matthew Deans.
3. Fernandez, A. M., & Jebbanema, L. (2007). The Effect of Surfactant Selection on
Emulsion Polymer Properties. Retrieved from
http://www.pcimag.com/articles/87271-the-effect-of-surfactant-selection-on-
emulsion-polymer-properties
4. An Implementation Recipe for Cascade Control. (2015). Retrieved from
http://controlguru.com/an-implementation-recipe-for-cascade-control/
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