This document provides an overview of process control applications in chemical industries. It discusses what process control is, why it is needed, common control techniques like feedback control, and examples of control systems for units like chemical reactors and boilers. Process control is used to maximize safety, quality and efficiency in chemical processes. It allows preserving product quality while optimizing production. The document also reviews various software and instruments used for process control and highlights its importance across many industrial sectors.

1. Chemical Engineering Process Control
Process Control Applications in Chemical Industries
Instructor
Dr. Goran Abdulrahman
Prepared by:
Safeen Yaseen Ja’far
Ibrahim Ali
Submitted on
3/12/2022
Koya University
Faculty of Engineering
Department of Chemical Engineering
Fourth Stage/2022-2023

2. Table of Content
Abstract........................................................................................................................................................1
1. Introduction.............................................................................................................................................2
1.1 Introduction to Process Control ......................................................................................................2
1.2 A brief History of Process Control ..................................................................................................2
2. Literature Review & Methodology........................................................................................................3
2.1 What is a Process & Process Control?............................................................................................3
2.2 Why do we need Process Control? (Advantages of Process Control) ..........................................3
2.3 What disciplines can Process Control be used in? .........................................................................4
2.4 Control basics....................................................................................................................................4
2.4.1 Feedback controllers..................................................................................................................4
2.5 Software and products used to help with Process Control............................................................5
2.6 Industrial Applications of Process Control ....................................................................................5
2.6.1 Control of a Unit Operation in chemical industries................................................................6
2.6.2 An example of control system in chemical industry – Boiler Automation and Control of
the boiler. .............................................................................................................................................7
2.6.3 Chemical Reactor Temperature Control System....................................................................8
3. Conclusion ...............................................................................................................................................8
4. References................................................................................................................................................9

3. 1 | P a g e
Abstract
This report presents the process control overview and applications of control system in some units
in various industries. As we know the process control Process control is used in order to maximize
production while maintaining a desired level of product quality and safety and making the process
more economical. So, in this report also we discuss about the advantages of efficient control
system. Also, in this report we have some real or industrial example of control system.

4. Page | 2
1. Introduction
1.1 Introduction to Process Control
The electrical components that make up a process control system give manufacturing processes
stability, accuracy, and the elimination of dangerous transition states. Energy supply units and
machines can both have varied arrangements and implementations for operating systems. By
linking programmable logic controllers and a central computer, complicated operational tasks have
been solved as technology advances swiftly. A high level of exploitation and process coordination
are made possible by the capabilities for communication among instruments in addition to
connections with other devices (such as operating panels, motors, sensors, switches, valves, etc.).
In addition, implementing a process control system can be done with more freedom. No matter
how small, each component of a process control system is crucial. (MIKROE, 2022).
Process control is used to increase output while preserving the appropriate level of product quality
and safety and improving process efficiency. Process control systems are employed in factories
that make chemicals, pulp and paper, metals, food, and pharmaceuticals because these objectives
pertain to a number of businesses (Hahn, J. and Edgar, T.F., 2014).
Figure 1: Industrial Control System Diagram
1.2 A brief History of Process Control
Pneumatic and hydraulic systems were used in early mechanical process controllers. Since the
control valve the most common ultimate control element is by nature a mechanical device,
mechanical engineers were frequently employed in the field of control engineering. Analog
electronic systems gradually took the place of pneumatic controllers. Faster connection between
field equipment and controllers in a central control center, space savings, and certain upgraded
features were all advantages of using electronics. In general, they resembled pneumatic controls,
but mechanical engineers started to lose ground to electrical engineers in the field of control
engineering. In order to offer interlocks, logic control, and sequence control, relay systems were
used (Heavner and Emerson, 2017).

5. Page | 3
2. Literature Review & Methodology
2.1 What is a Process & Process Control?
Process: In its broadest sense, a process is an action that makes use of resources to convert inputs
into outputs. It is the source of the energy needed for the transformation process to take place.
(Nash. D., 2015).
Process Control: Process control basically refers to preserving the desired state of a chemical
system by modifying the chosen process variable. It is about science and technology. The process
variables can be temperature (T), Pressure (P), Level (L), flow rate (F), etc., (Partha Pratim Panja,
2022).
Figure 2: Typical process control system block diagram
2.2 Why do we need Process Control? (Advantages of Process Control)
Effective process control is required to maintain safe operations, quality products, and business
Viability (Nash. D., 2015).
• Safety: The primary purpose of a Process Control system is safety: personnel safety,
environmental safety and equipment safety.
• Quality: In addition to safety, process control systems are central to maintaining product
quality. In blending and batching operations, control systems maintain the proper ratio of
ingredients to deliver a consistent product.
• Profit: When safety and quality concerns are met, process control objectives can be focused
on profit. All processes experience variations and product quality demands that we operate
within constraints.

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2.3 What disciplines can Process Control be used in?
There are a number of different disciplines and workplace specialties in which process control can
be used such as:
• Engineering: Engineers are typically responsible for designing process control systems and
machinery.
• Software and systems development: Software and systems designers and developers are
typically responsible for software-based systems that interface with the physical machinery
used for process control.
• Operations: Operations personnel, such as supervisors and their workers, are responsible for
monitoring process control equipment to ensure that it is functioning properly, and without
errors.
• Quality assurance: QA is still required in plants that use process control – to catch errors and
mistakes, adjust process control systems, and take other such necessary actions that are
required to ensure perfect product quality, safety, and efficiency (Black. P., 2019).
2.4 Control basics
The vast majority of process reactions can be divided into self-regulating and non-self-regulating
types (or integrating). Self-regulating processes adjust their steady-state value in response to a
change in the process input. For instance, the substance being heated will reach a new temperature
if steam is added to a heat exchanger (Nash. D., 2015).
2.4.1 Feedback controllers
A feedback controller is typically used for process control (Figure 3). It is possible to alter some
process inputs to direct significant process observations toward objectives or setpoints. Other
process observations are not required to be kept within upper or lower constraint limits, but they
cannot be managed to a target setpoint either (Nash. D., 2015).
Figure 3: Most process control is accomplished by using a feedback control loop (Nash. D.,
2015).

7. Page | 5
2.5 Software and products used to help with Process Control
Particularly when it comes to process control in manufacturing, every process control system is
unique. Let's explore some of the various software programs and solutions used to assist with
process control, ranging from custom-built process control instrumentation to cloud-based
software packages. now (Black. P., 2019).
▪ Process control software
▪ Process control instrumentation
▪ Sensors and monitoring systems
▪ QA programs and software
▪ Analytics and data warehousing systems
Figure 4: Screenshot of MPC in a typical application courtesy of Siemens
2.6 Industrial Applications of Process Control
Process control, as previously said, is often employed in any business where continuous production
takes place, that is, if a product or material is continuously produced with little to no downtime. In
light of this, let's quickly examine some of the major sectors using process control systems: and
their applications.
• Pharmaceuticals: Extreme precision is required when creating pharmaceutical medications.
Even minor errors can render a batch of medication or other such products completely
unusable.
• OEM and manufacturing: Manufacturing companies of all types can make use of process
control.
• Pulp and paper: Process control is extremely important in the pulp and paper industry.
• Semiconductor companies: Manufacturers of semiconductors (microchips), such as Intel,
AMD, Nvidia, and others, make extensive use of process control.

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• Petrochemicals: Consistency is absolutely key in the petrochemical industry, particularly
when creating products such as high-quality rubber and petroleum-derived plastics.
• Power generation: Power plants do not generate a physical product, but rather generate
electricity and power to be used elsewhere – and they must do so constantly, so they always
Food and dairy: Earlier, we gave an example of the use of process control in the pasteurization
of milk.
• Water: Water treatment is an ideal application for process control, as the input (wastewater,
seawater, etc.) never stops – and can vary quite a bit in composition.
• Oil & gas: Oil and gas pipelines must deliver a constant, steady stream of oil or gas, and be
maintained at the proper pressure.
2.6.1 Control of a Unit Operation in chemical industries
Equipment for control systems often has a lengthy lifespan in industrial plants since installing
replacements entails high capital expenditures, a significant time commitment, and output loss.
Therefore, newly hired engineers may come upon instrumentation and control technology that has
been in use for more than 20 years. (JOSEPH ALFORD, GEORGE BUCKBEE, P.E., 2020).
Figure 5: Personal computers (PCs), programmable logic controllers (PLCs) and distributed
control systems (DCSs) are options for providing process control for a unit operation. These
computer-based systems interface to process equipment via input/output (I/O) subsystems. PLCs
and DCSs typically interface with other plant computers through a local area network (LAN)
(JOSEPH ALFORD, GEORGE BUCKBEE, P.E., 2020).

9. Page | 7
2.6.2 An example of control system in chemical industry – Boiler Automation and Control
of the boiler.
The goal of boiler automation is to ensure boiler safety and stop potentially harmful situations
from happening. Therefore, the boiler automation must be both quick and educational, and it must
be able to provide the operator with a tool so that he can operate the boiler. The modularity is taken
into consideration when designing the hardware and software for automation. As a result, the entire
automation solution is simple to manage and grow as necessary. High performance, safe and
dependable operation, and a high level of integration are the essential requirements for boiler
automation. The boiler plant has been completely automated as a single unit. From the main control
room, which also has identical workstations at the water plant, fuel handling, and maintenance
rooms, the entire power production is managed. The control room can be ergonomically
constructed because one system controls the entire facility. The workforce can be maintained to a
minimum if the facility is set up to run on one-man shifts.
Figure 6: Block Diagram of Boiler Automation

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2.6.3 Chemical Reactor Temperature Control System
As a single entity, the boiler plant has been fully automated. The entire power production is
monitored from the main control room, which also contains identical workstations at the water
plant, fuel handling, and maintenance rooms. One system manages the entire facility, therefore the
control room may be built ergonomically. If the facility is configured to run on one-man shifts, the
personnel can be kept to an absolute minimum (Editorial Staff, 2022).
:
Figure 7: A P&ID above shows the inter-relationships of the process piping, vessels, and
instruments
3. Conclusion
As we discussed in previous sections, process control has many applications and it is important
and useful for daily life applications if the process control is efficient, we can conclude all sections
before as following:
✓ energy savings: When your plant and machinery are run efficiently, energy waste is reduced.
✓ improved safety: By automatically alerting you to any abnormalities, control systems reduce
the likelihood of accidents.
✓ consistent product quality: variations in product quality are kept to a minimum and reduce
your wastage.
✓ lower manufacturing costs: detecting faults early means throughput, yield and quality are
maintained.
✓ improved environmental performance - systems can give you an early warning of a rise in
emissions.

11. Page | 9
4. References
1. MIKROE. 2022. introduction-process-control-system. [online] Available at:
https://www.mikroe.com/ebooks/introduction-to-plc-controllers/introduction-process-
control-system [Accessed 3 Dec. 2022].
2. Hahn, J. and Edgar, T.F. 2014. Process Control. Kirk-Othmer Encyclopedia of Chemical
Technology, pp.1–44. Available at:
http://dx.doi.org/10.1002/0471238961.1618150307091522.a01.pub3 [Accessed 24 Nov.
2022].
3. Heavner, L., 2017. Control Engineering for Chemical Engineers. [online]
ChemEngOnline. Available at: https://www.chemengonline.com/process-control-for-
chemical-engineers/?printmode=1. [Accessed 24 Nov. 2022].
4. Panja, P.P. (2022). What is Process Control? Its Importance and Working Principle
(PDF). [online] What is Piping. Available at: https://whatispiping.com/process-control/.
[Accessed 24 Nov. 2022].
5. Nash. D., 2015. Fundamentals of Instrumentation and Process Control by Dennis Nash
[ebook] PDFDrive Available at: https://www.pdfdrive.com/fundamentals-of-
instrumentation-and-process-control-e9772561.html [Accessed 24 Nov. 2022].
6. Black. P., 2019. Process Control – Everything You Need To Know [Detailed Review].
[online] processindustryinformer. Available at:
https://www.processindustryinformer.com/process-control-everything-you-need-to-
know/#What-is-the-importance-of-Process-Control-What-are-its-benefits. [Accessed 24
Nov. 2022].
7. JOSEPH ALFORD, GEORGE BUCKBEE, P.E., 2020. Industrial Process Control
Systems: A New Approach to Education. [online] Available at:
https://www.aiche.org/resources/publications/cep/2020/december/industrial-process-
control-systems-new-approach-education. [Accessed 24 Nov. 2022].
8. IEEE Standard for Information TechnologyPortable Operating System Interface
(POSIX(R)) Base Specifications, Issue 7 - Technical Corrigendum 1. 2013. New York,
Ny, Usa Ieee. [Online] Available at:
https://www.ijareeie.com/upload/2016/january/11_Effective.pdf [Accessed 24 Nov.
2022].
9. Staff, E. 2015. Chemical Reactor Temperature Control System. [online] Inst Tools.
Available at: https://instrumentationtools.com/example-chemical-reactor-temperature-
control-system/. [Accessed 24 Nov. 2022].