Process Industry

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

2. Agenda Overview of Process Industries Process Industry – Continuous Process Process Industry – Batch Process Batch & Continuous Process Comparison

3. 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? To increase labor productivity To reduce labor cost To overcome the effects of labor shortages To reduce or remove routine manual and clerical tasks To improve worker safety To improve product quality To reduce manufacturing lead time To accomplish what cannot be done manually

4. Overview of Process Industries What are Process industries? T he 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 Fo od, beverages, Petrochemicals, pharmaceuticals, oil & gas, Iron & Steel, Power plant , wood and wood products, paper and paper products, etc.

5. 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.

6. 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

7. Batch & Continuous Process Comparison Content Batch Process Continuous Process Types of m aterials 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 the entire reaction process.

8. 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 with the conclusion of the reaction. Continuous extraction of products at all times during the reaction. Trouble shooting A fault or dealing with a batch requiring “repair” does not cause problems in the other stages. Appropriate tests are conducted after each stage. The installations are interconnected, so a fault in one causes a stoppage in all the others. Material that has been damaged cannot be repaired under the same working conditions. It must be isolated and the process restarted.

9. Batch & Continuous Process Comparison Content Batch Process Continuous Process Quantities produced Preferable when production of small quantities of a specific material are planned. Preferable for large scale production. Variety of products in the plant Preferable when the plant produces a wide variety of materials and when the product is likely to be changed now and again, while using the same reactor. Preferable for a central and permanent 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 is smaller. Preferable after the conclusion of all the stages of grossing-up and economic feasibility tests.

10. Q&A

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