2) Control Systems in the Sugar Refining Process

❖ Control Loop 1
The temperature in the dilution tank is controlled by feedback control system by using temperature
transmitter that sends an electrical signal to temperature controller which compute the error and
after that sending a pneumatic signal to final control element (valve). The action: must be taken
by controller when the temperature in the tank is law the controller send signal to valve to open,
and vice versa.
Controlled Variable temperature in the dilution tank
Manipulated Variable inlet flow rate of steam
Disturbance outlet flow rate of the tank

❖ Control Loop 2
The temperature in the preparation tank is controlled by feedback control system by using
temperature transmitter that sends an electrical signal to temperature controller which compute the
error and after that sending a pneumatic signal to final control element (valve). The action: must
be taken by controller when the temperature in the tank is law the controller send signal to valve
to open, and vice versa.
Controlled Variable temperature in the preparation tank
Manipulated Variable inlet flow rate of steam
Disturbance outlet flow rate of the tank (F1)

❖ Control Loop 3
The Density of the syrup leaving the preparation tank is adjusted by controlling the flow rate is
controlled by feedback control system by using flow rate transmitter that sends an electrical signal
to flow rate controller which compute the error and after that sending a pneumatic signal to final
control element (valve). The action: must be taken by controller when the flow rate in the tank is
too high, the density will decrease, the controller send signal to valve to close.
Controlled Variable Density of the syrup leaving the preparation tank is adjusted by
controlling the flow rate of the tank.
Manipulated Variable outlet flow rate of stream.
Disturbance inlet temperature of stream (f2).

❖ Control Loop 4
The level in the preparation tank is controlled by feedback control system by using level transmitter
that sends an electrical signal to level controller which compute the error and after that sending a
pneumatic signal to final control element (valve). The action: must be taken by controller when
the level in the tank is law the controller send signal to valve to open, and vice versa.
Controlled Variable level in the preparation tank
Manipulated Variable inlet flow rate of stream (F2)
Disturbance outlet flow rate of the tank (F1)

❖ Control Loop 5
The level in the 50% acid tank is controlled by feedback control system by using level transmitter
that sends an electrical signal to level controller which compute the error and after that sending a
pneumatic signal to final control element (valve). The action: must be taken by controller when
the level in the tank is high the controller send signal to valve to close, and vice versa.
Controlled Variable Level in the 50% acid tank
Manipulated Variable inlet flow rate of water stream
Disturbance outlet flow rate from 75% acid tank

❖ Control Loop 6
The strength in the 50% acid tank is adjusted by controlling temperature which is controlled by
feedback control system by using temperature transmitter that sends an electrical signal to
temperature controller which compute the error and after that sending a pneumatic signal to final
control element (valve). The action: must be taken by controller when the temperature in the tank
is high the strength will decrease then; the controller send signal to valve to close.
Controlled Variable strength in the 50% acid tank is adjusted by controlling temperature
Manipulated Variable outlet flow rate of water stream
Disturbance outlet flow rate from 75% acid tank

❖ Control Loop 7
The temperature in the blending tank is controlled by feedback control system by using
temperature transmitter that sends an electrical signal to temperature controller which compute the
error and after that sending a pneumatic signal to final control element (valve). The action: must
be taken by controller when the temperature in the tank is law the controller send signal to valve
to open, and vice versa.
Controlled Variable temperature in the blending tank
Manipulated Variable inlet flow rate of steam
Disturbance outlet flow rate of the lime
3) Carbon monoxide Removal from Synthesis Gas
❖ Control Loop 1
The Temperature of superheated steam leaving E-15 is controlled by feedback control system by
using temperature transmitter that sends an electrical signal to temperature controller which
compute the error and after that sending a pneumatic signal to final control element (valve). The
action: must be taken by controller when the temperature in the superheater is law the controller
send signal to valve to open, and vice versa.
Controlled Variable Temperature of superheated steam leaving E-15
Manipulated Variable inlet flow rate in stream 1
Disturbance outlet flow rate of the stream A

❖ Control Loop 2
The pressure of superheated steam produced in E-15 is controlled by feedback control system by
using pressure transmitter that sends an electrical signal to pressure controller which compute the
error and after that sending a pneumatic signal to final control element (valve). The action: must
be taken by controller when the pressure in the superheater is high the controller send signal to
valve to close, and vice versa.
Controlled Variable Pressure of superheated steam produced in E-15
Manipulated Variable inlet flow rate of stream B
Disturbance outlet flow rate of stream A

❖ Control Loop 3
The level in boiler drum is controlled by feedback control system by using level transmitter that
sends an electrical signal to level controller which compute the error and after that sending a
pneumatic signal to final control element (valve). The action: must be taken by controller when
the level in the boiler drum is high the controller send signal to valve to close, and vice versa.
Controlled Variable Level in boiler drum
Manipulated Variable inlet flow rate of stream A
Disturbance outlet flow rate of stream C

❖ Control Loop 4
The pressure in deaerator is controlled by feedback control system by using pressure transmitter
that sends an electrical signal to pressure controller which compute the error and after that sending
a pneumatic signal to final control element (valve). The action: must be taken by controller when
the pressure in the deaerator is high the controller send signal to valve to open, and vice versa.
 Controlled Variable pressure in deaerator
Manipulated Variable outlet flow rate of stream D
Disturbance inlet flow rate of stream 16

❖ Control Loop 5
The level in deaerator is controlled by feedback control system by using level transmitter that sends
an electrical signal to level controller which compute the error and after that sending a pneumatic
signal to final control element (valve). The action: must be taken by controller when the level in
the deaerator is high the controller send signal to valve to close, and vice versa.
Controlled Variable Level in deaerator
Manipulated Variable inlet flow rate of stream E
Disturbance inlet flow rate of stream 16

❖ Control Loop 6
The flow of low-pressure makeup steam to deaerator is controlled by feedback control system by
using flow transmitter that sends an electrical signal to flow controller which compute the error
and after that sending a pneumatic signal to final control element (valve). The action: must be
taken by controller when the flow of low-pressure makeup steam in the deaerator is high the
controller send signal to valve to close, and vice versa.
Controlled Variable Flow of low-pressure makeup steam to deaerator
Manipulated Variable inlet flow rate of low-pressure makeup steam
Disturbance inlet temperature of low-pressure makeup steam

❖ Control Loop 7
The Temperature of feed gas leaving E-l3 going to reboiler E-l 1 is controlled by feedback control
system by using temperature transmitter that sends an electrical signal to temperature controller
which compute the error and after that sending a pneumatic signal to final control element (valve).
The action: must be taken by controller when the temperature in the Economizer is law the
controller send signal to valve to close, and vice versa.
Controlled Variable Temperature of feed gas leaving E-l3 going to reboiler E-l 1
Manipulated Variable inlet flow rate in Economizer
Disturbance inlet temperature of Economizer

❖ Control Loop 8
The Temperature of feed gas into absorber C- 6 is controlled by feedback control system by using
temperature transmitter that sends an electrical signal to temperature controller which compute the
error and after that sending a pneumatic signal to final control element (valve). The action: must
be taken by controller when the temperature in the absorber is law the controller send signal to
valve to open, and vice versa.
Controlled Variable Temperature of feed gas into absorber C- 6
Manipulated Variable inlet flow rate in stream 2
Disturbance outlet temperature of the stream F

❖ Control Loop 9
The level in regenerator C-7 is controlled by feedback control system by using level transmitter
that sends an electrical signal to level controller which compute the error and after that sending a
pneumatic signal to final control element (valve). The action: must be taken by controller when
the level in the regenerator is low the controller send signal to valve to open, and vice versa.
Controlled Variable Level in regenerator C-7
Manipulated Variable inlet flow rate of feed stream (F)
Disturbance outlet flow rate of bottom of regenerator C-7 (G)

❖ Control Loop 10
The Temperature in bottom of regenerator C-7 is controlled by feedback control system by using
temperature transmitter that sends an electrical signal to temperature controller which compute the
error and after that sending a pneumatic signal to final control element (valve). The action: must
be taken by controller when the temperature in the regenerator is law the controller send signal to
valve to close, and vice versa.
Controlled Variable Temperature in bottom of regenerator C-7.
Manipulated Variable inlet flow rate of bottom of regenerator C-7 (G)
Disturbance inlet temperature of the feed stream F

❖ Control Loop 11
The Temperature of synthesis gas between the two stages of compressor and exit temperature is
controlled by feedback control system by using temperature transmitter that sends an electrical
signal to temperature controller which compute the error and after that sending a pneumatic signal
to final control element (valve). The action: must be taken by controller when the temperature in
the compressor is high the controller send signal to valve to close, and vice versa.
Controlled Variable Temperature of synthesis gas between the two stages of compressor
and exit temperature.
Manipulated Variable inlet flow rate of top product (4)
Disturbance outlet temperature of the exit stream (X)
5) Ammonium Nitrate Prilling Plant Control System
❖ Control Loop 1
The level in the evaporator is controlled by feedback control system by using level transmitter that
sends an electrical signal to level controller which compute the error and after that sending a
pneumatic signal to final control element (valve). The action: must be taken by controller when
the level in the evaporator is high the controller send signal to valve to open, and vice versa.
Controlled Variable the level in the evaporator.
Manipulated Variable outlet flow rate of stream A
Disturbance inlet flow rate from weak NH4NO3 tank

❖ Control Loop 2
The pressure in the evaporator is controlled by feedback control system by using pressure
transmitter that sends an electrical signal to pressure controller which compute the error and after
that sending a pneumatic signal to final control element (valve). The action: must be taken by
controller when the pressure in the evaporator is high the controller send signal to valve to open,
and vice versa.
Controlled Variable the pressure in the evaporator.
Manipulated Variable flow of air to the exit pipe of the evaporator.
Disturbance inlet temperature from weak NH4NO3 tank

❖ Control Loop 3
The level in the surge tank is controlled by feedback control system by using level transmitter that
sends an electrical signal to level controller which compute the error and after that sending a
pneumatic signal to final control element (valve). The action: must be taken by controller when
the level in the surge tank is high the controller send signal to valve to open, and vice versa.
Controlled Variable The level in the surge tank
Manipulated Variable outlet flow rate of surge tank
Disturbance inlet flow rate of surge tank

❖ Control Loop 4
The temperature of the dried pellets leaving the dryer is controlled by feedback control system by
using temperature transmitter that sends an electrical signal to temperature controller which
compute the error and after that sending a pneumatic signal to final control element (valve). The
action: must be taken by controller when the temperature in the dryer is law the controller send
signal to valve to close, and vice versa.
Controlled Variable temperature of the dried pellets leaving the dryer.
Manipulated Variable outlet flow rate of dryer
Disturbance inlet temperature of the air