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Summer training report

Abstract
The aim of training to practice on modeling, process simulation, control and
lab working on batch pilot plant and continuous distillation column and study
how to make analysis for ethanol and water

Table of Contents
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Abstract...................................................................................................................... 2
Introduction................................................................................................................ 4
A.

Process simulation............................................................................................... 4

B.

Modeling.............................................................................................................. 5

C.

Continues Distillation piglet plant........................................................................6

D.

Batch reactor....................................................................................................... 7

E.

Multi Product and multipurpose Batch pilot plant................................................8

F.

gas chromatography.......................................................................................... 10

Sources of Error........................................................................................................ 11
Bibliography............................................................................................................. 12

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Introduction

A. Process simulation
Process simulation is important in chemical industry as it save money as it
provides the processer with a variety of choices to select the best suitable
option to carry out the process as it is used in design, analysis and optimized
the technical process which serves the chemical field as in chemical plants
and the chemical process. Process simulation has economic advantages as it
save money which can be lost in the process. For example if we have car
body and the designer has to choose the best engine for the body so if he
used to buy many engines so he will lose money and the best engine will be
used at the end so process simulation is used to select the best alternative
for the designer to be perfect for the body of the car without losing money
for buying many engines and select the best one.
Process simulation defines the process in flow chart as process simulation
programs as Aspen Plus which used in training which used to make the
process in flow chart. As in this diagram.

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B. Modeling
Modeling is defining the real Process in chemical equations in charge of
energy, mass, Flow rates and thermodynamic of the process. Which used in
setting the process for simulation which used to develop the chemical
process with developing the variables of energy. New models take several
ways to be improved to improve the process simulation. After modeling
Process simulation take place after making the equations on the program
which used in training which Aspen Plus is.

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C. Continues Distillation piglet plant


Distillation is a separation technique used for two immiscible liquids based on the difference of
Their boiling points . our automated continuous distillation unit allows the user to define and
Control the parameters of distillation process, carry out calculations on the data fed manually or
Automatically received from the process instruments and even save the data and results for
evaluation or future use. The unit includes complete glass assembly with required
Instrumentation such as heating mantle, sensors, flow controllers Weatherproof local panel and
SCADA system for defining of and controlling of process parameters.
There two types of Distillation column:

Packed column (Different packing can be provided such as Raschig rings, Pall rings,
Intalox saddles etc.)
Sieve Tray column (Sampling points and thermometer
pockets can be provided at different trays so that the tray hold-up can be collected for
further evaluation, if required.

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D.Batch reactor
Batch reactor is the generic term for a type of vessel widely used for a variety of process
operations such as solids dissolution, product mixing, chemical reactions, batch distillation,
crystallization, liquid/liquid extraction, polymerization etc. We offer batch reactors consisting of
a tank with an agitator and integral heating/cooling system (Electric heating, jacketed
heating/cooling, double jacketed) in Glass and Metal up to 300L capacity. Various parameters
can be measured and controlled such as Temperature, Pressure, Ph, Torque, Turbidity, Dissolved
oxygen content, Stirring speed etc. depending on the requirement of the process.

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E. Multi Product and multipurpose Batch pilot plant


The aim was to obtain ethanol from a mixture of ethanol and water with
purity 75 % as a minimum purity by weight.

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The objective is to operate a batch piglet plant controlled by programmable


logical controller, In addition operate batch vacuum distillation column,
Transfer

between

containers

and

analyze

the

samples

using

gas

chromatography. Firstly 4 liters of synthetic alcohol mixture prepared, check


the composition of the synthetic alcohol mixture which is the feed sample
using gas chromatograph.The procedure of the work was after checking the
composition, However the feed was charged in the R2 column, Then going to
programmable logical controller which is the PLC adjust the temperature to
130C, Water is circulated to the condenser, By opening specified valves,
adjusting the agitation to 300 rpm, Then check that the valves are closed
and start the vacuum pump with pressure to 0.9, then Column R2 valve is
open after the pressure being constant , the pressure should be decreased to
0.5 atmosphere, Then activate the top control loop and the product will be
obtained in one of the containers. Finally the shutting down process is
proceed which is switch off the heater and wait for 30 min, closing the
vacuum pump, open both vacuum valves, Stop the top controller, Close
stirrer and empty the container and clean it with distillate water. So after
calculation the composition of ethanol is feed was 7.85659%, and ethanol in
the top product is 80.56% and the bottom ethanol was 99.97%, These
calculation has difference in the composition of ethanol due to reflex rate
which return some of the top product to the reactor so the bottom stream
has much more composition of ethanol than the top.

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F. gas chromatography
A gas chromatograph (GC) is an analytical instrument that measures the content of various
components in a sample. The analysis performed by a gas chromatograph is called gas
chromatography. Principle of gas chromatography: The sample solution injected into the
instrument enters a gas stream which transports the sample into a separation tube known as the
"column." (Helium or nitrogen is used as the so-called carrier gas.) The various components are
separated inside the column. The detector measures the quantity of the components that exit the
column. To measure a sample with an unknown concentration, a standard sample with known
concentration is injected into the instrument. The standard sample peak retention time
(appearance time) and area are compared to the test sample to calculate the concentration.

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Sources of Error
There are two types of Errors:
1. systematic errors
2. Random errors which are caused by human readings and the
surrounding errors.

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Bibliography
1- (Universitat Rovira i Virgili, 2008),http://www.urv.cat/

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