Chemical Industry - A Guide to Level and Flow Controls for the Chemical Industry
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Chemical Industry - A Guide to Level and Flow Controls for the Chemical Industry - 1

A Guide to Level and Flow Controls for the Chemical Industry I N D U S T R Y A P P L I C A T I O N S S E R I E S

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Chemical Industry - A Guide to Level and Flow Controls for the Chemical Industry - 2

2 1 2 3 3 4 REBOILER TOWER CONDENSER CONDENSER REFLUX DRUM 1-4: Distillation TO STORAGE 5: Liquid Extraction LIGHT PHASE HEAVY PHASE MIXING SETTLING 5 6 6: Vapor/Liquid Separation VAPOR OUT LIQUID OUT FEED CLEAN AIR OUT SCRUBBER WATER IN SCRUBBER WATER OUT DIRTY AIR IN 7: Scrubber Vessel 9 7 Leading Level and Flow Chemical Applications Liquid Level Applications: The following level applications utilize level instruments for process control. A separate alarm using a different technology often serves as a back-up for spill detection. 1. Distillation Tower 2. Reboiler 3. Condenser 4. Reflux...

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Chemical Industry - A Guide to Level and Flow Controls for the Chemical Industry - 3

3 7 IN PRODUCT 8: Mixing Vessel 8 HEAT STEAM PRODUCT 9: Chemical Reactor COOLANT SOLVENT, RAW MATERIAL OR REACTANT STERILIZATION STEAM PRODUCT 10: Fermentation Vessel STERILE AIR OFF-GAS 14: Chlor-Alkali HYDROGEN CHLORINE GAS GAS CAUSTIC 11: Steam Drum FEED WATER PRODUCT CATALYST GAS FEED GAS OUT 12 13: Catalysis Vessel 12 12: Surge Drum INLET OUTLET VENT 15: Chemical Injection 16: Deionization WASTEWATER 18: Neutralization TREATED WATER ACID & CAUSTIC FEED 18 17: Waste Sump 11 STEAM 13 14 15 UNTREATED 16 WATER TREATED WATER 19-20: Storage Tanks 19 20 21 22 23 24 21-24: Flow Applications 9...

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Chemical Industry - A Guide to Level and Flow Controls for the Chemical Industry - 4

Application: Selecting a separation technology from among 20 leading varieties depends upon a chemical’s nature, the number of phases, and the capacity, speed and efficiency required. Distillation—separating substances based on differences in volatilities—is the most widely used separation and purification method. Today, approximately 40,000 distillation towers are operating in U.S. chemical plants. Challenges: Level measurement at the bottom of a distillation tower controls the “bottoms” product rate. Poor level control could allow liquid to back up over the stripping trays causing damage...

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Chemical Industry - A Guide to Level and Flow Controls for the Chemical Industry - 5

Application: A heat transfer process that changes a gas or vapor to a liquid, condensation is employed in the reflux process to improve the efficiency of distillation. Condensation can also be employed for producing saturated liquid products, for sub-cooling, or to serve an environmental or vapor recovery function. Condensation is carried out in a variety of configurations. Challenges: In the distillation process, tower vapors are condensed prior to entering an accumulator. The condenser’s level can be used to control tower pressure where the liquid level set point serves as the manipulated...

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Application: Liquid-liquid extraction (LLX), or solvent extraction or partitioning, is a selective separation procedure for isolating and concentrating a valuable substance from an aqueous solution by using an organic solvent. LLX can serve as an alternative when distillation is ineffective. LLX is used in pharmaceutical, food and agricultural processing, organic and inorganic chemistry, hydrometallurgy and fragrances. Challenges: In mixer-settler type extraction, feed and solvent tanks are monitored for level. The feed and solvent are thoroughly blended in a mixer-settler chamber and the...

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Chemical Industry - A Guide to Level and Flow Controls for the Chemical Industry - 7

Application: Scrubbers remove odors, pollutants, acid gases and chemical wastes from air and liquid streams. In a wet scrubber, the polluted stream flows counter currently past water or a liquid chemical which removes the undesirable component of the gas or liquid. Chemical scrubbing typically requires large amounts of caustic chemicals. Challenges: Accurate level monitoring of the scrubbing water necessitates a control to automatically feed the correct amount of make-up water to the recycle reservoir either continuously or on a periodic basis. Located in the wet scrubber shell, the level...

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Chemical Industry - A Guide to Level and Flow Controls for the Chemical Industry - 8

Application: Chemical, polymerization and pharmaceutical processes utilize reactor vessels to contain chemical reactions. Chemical reaction speed and product quality are frequently controlled by an external heat exchanger for elevating temperature and a cryogenic system for lowering temperature. Reactors typically contain impellers for product mixing. Challenges: Level instrumentation in a tank-type reactor vessel must contend with diverse and often aggressive product chemistries, agitation, mixing, surface foam and temperature and pressure variations. Low level monitoring in the discharge...

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Chemical Industry - A Guide to Level and Flow Controls for the Chemical Industry - 9

Application: Chemical manufacturers are major users of steam for cleaning, drying, fermentation, steam stripping, and chemical recovery. Steamingin- place (SIP) is a widely used method for in-line sterilization of vessels, valves, process lines, and filter assemblies. Steam is created in a boiler where heat transforms water under pressure into steam. Challenges: Boiler drum level control is critical for safe and efficient steam generation. Drum level control maintains level at constant steam load. Too low a level may expose boiler tubes, which will overheat and sustain damage. Too high a...

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Chemical Industry - A Guide to Level and Flow Controls for the Chemical Industry - 10

Application: The catalytic method of converting compounds into other compounds uses a chemical catalyst to increase the rate of a reaction. The catalyst is chemically unchanged after the reaction has occurred and can be recovered from the reaction mixture. Thirty of the top fifty commodity chemicals are created directly by catalysis. Challenges: In the fluidized bed reactor-regenerator (FBRR) a fluid is passed through the catalyst at high enough velocities to suspend the solid and cause it to behave as though it were a fluid. Measurement in the reactor vessel must contend with severe...

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Application: From Active Pharmaceutical Ingredients (APIs) to Vapor Phase Corrosion Inhibitors (VCIs), any one of a thousand additives and agents can be injected into the process stream of a given industry to alter or impart new product properties or enhance processing dynamics. Injection systems and chemical skid systems offer a wide range of dosing control options. Challenges: A chemical injection system typically consists of one or more chemical supply tanks or drums, a metering tank, a vessel with a mixer (if required), a variable pump, and process controls. Chemical tanks and chemical...

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