In this session you will learn: Overview of Process Industries Process Industry – Continuous Process Process Industry – Batch Process Batch & Continuous Process Comparison

1. Industrial Automation Training
Process Industry

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Agenda
• Overview of Process Industries
• Process Industry – Continuous Process
• Process Industry – Batch Process
• Batch & Continuous Process Comparison

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Overview of Industrial Automation
What is Industrial Automation?
Industrial Automation is defined by the Automation Federation as "the
creation and application of technology to monitor and control the
production and delivery of products and services.
Why is Automation required in Process Industries?
• Toincrease labor productivity
• Toreduce labor cost
• Toovercome the effects of laborshortages
• Toreduce or remove routine manual and clericaltasks
• Toimprove worker safety
• Toimprove product quality
• Toreduce manufacturing lead time
• Toaccomplish what cannot be donemanually

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Overview of Process Industries
What are Process industries?
The process industries are those industries where the primary production
processes are either continuous, or occur on a batch of materials that is
indistinguishable
Today the process industries produce a wide variety of products that are
essential for modern industrialized societies.
The operation of modern industrial plants would not be feasible without
automation and process control.
Examples of Process Industries
Food, beverages, Petrochemicals, pharmaceuticals, oil & gas, Iron &
Steel, Power plant, wood and wood products, paper and paper products,
etc.

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Process Industry – Continuous Process
What is a continuous process?
A streamlined process that involves ongoing production of end products .In simple
words, this process keeps going on 24-hours a day and 7 days a week.
This is consistent, constant, and uninterrupted.
A continuous process plant is designed so that there is a seamless flow of the
product from one machine or robot station to another through the production
process.
Manufacturers most often use this type of process in the manufacture of chemicals,
drugs, and glass, as well as in the refining process for crude oil.

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Process Industry – Batch Process
What is a batch process?
The batch process is a single- or multi-stage process in which a certain quantity
of inputs (raw materials) are fed into the chemical reaction unit (of the entire
reaction) under conditions suitable for obtaining the desired reaction
(temperature, pressure, required time, etc.).
In batch process, in the reactor and at any given period of time, various actions
take place in the wake of which a concentration of reactants and products varies
so long as the reaction progresses.
At the conclusion of the process the mixture is removed from the reactor and it
then undergoes the appropriate separation and processing stages (either
physical or chemical) at the required level of cleanliness. This is generally
dictated by the customers for whom the specific product is manufactured.
Manufacturers most often use this type of process in bakeries, sports shoes
manufacturing, pharmaceutical ingredients, purifying water, inks, paints &
adhesives

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Batch & Continuous Process Comparison
Content Batch Process Continuous Process
Types of
materials
Can be used with all
types of materials (with
non-flow materials, it is
easier to use the batch
process).
Easier for use with flowing
materials (today, almost any
material can be produced
with the continuous
process; investment cost is
the decisive factor).
Reactor Installation size Relatively large
installations. Very big
investment in land and
installations.
Relatively small
installations. Significant
savings in land and
installations.
Feeding raw
materials
Raw materials are fed
before the start of the
reaction.
Constant feeding of raw
materials during theentire
reaction process.

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Batch & Continuous Process Comparison
Content Batch Process Continuous Process
Control of the set of
actions in the system
Simple control. It is easier to
control reaction conditions (pH,
pressure, temperature). Manual
control can also be done.
Complex control. Automatic control
must be used. Control of reactor
conditions is more difficult. Control
must be exercised over the rate of flow
of the materials.
Product(s) Extraction of materials only after
all the actions are finished withthe
conclusion of the reaction.
Continuous extraction of productsat
all times during the reaction.
Trouble shooting A fault or dealing with a batch
requiring “repair” does notcause
problems in the other stages.
Appropriate tests are conducted
after each stage.
The installations are interconnected,
so a fault in one causes a stoppagein
all the others. Material that hasbeen
damaged cannot be repaired under
the same working conditions. It must
be isolated and the processrestarted.

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Batch & Continuous Process Comparison
Content Batch Process Continuous Process
Quantities produced Preferable when productionof
small quantities of a specific
material are planned.
Preferable for large scale production.
Variety of productsin
the plant
Preferable when the plant
produces a wide variety of
materials and when the productis
likely to be changed now and
again, while using the same
reactor.
Preferable for a central andpermanent
product.
Product development
stage
Preferable when the process is
relatively new and still unfamiliar.
In this case the initial investment
is in a smaller batch reactor, and
thus the economic risk issmaller.
Preferable after the conclusion ofall
the stages of grossing-up and
economic feasibility tests.

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Q&A

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Post Test
Questioner:
Choose the best answer
1. Industrial automation aids to .
a. Increase Labor productivity ,improve product quality, increase manufacturing lead
time.
b. Decrease Labor productivity ,reduce product quality, increase manufacturing lead
time.
c. Increase Labor productivity ,improve product quality, reduce manufacturing lead
time.
2. Washing machine/laundry machine is a Process
a. Batch Process
b. Continuous Process
3. Power Plant is a Process.
a. Batch Process
b. Continuous Process