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2.1 Discuss the four (4) reasons why it is important to effectively control the manufacturing processes. 2.2 Condensed products produced in a continuous stirred tank
2.1 Discuss the four (4) reasons why it is important to effectively control the manufacturing processes. 2.2 Condensed products produced in a continuous stirred tank reactor (CSTR) are stored in a tank. The level controller for the storage tank is located at a predetermined place on top of the tank. Materials in the reactor would become clogged if this tank were to be full. So, if the tank exceeds 90% capacity, the level controller activates an alert if there is a problem and sends an electric signal, which opens an emergency drainage line placed at the bottom of the tank. Also, the level controller will sound an alarm to let plant staff know there is a problem with the storage tank. Lastly, if the storage tank fills, the level controller will also close the inlet valve. Represent this process with a proper piping and instrumentation diagram. 2.3 Isopropyl alcohol, water vapor, hydrogen, and other reactor exit gases that have not yet been reacted are delivered to a condenser, where the majority of the acetone, water vapor, and alcohol condense away and are only marginally present as gases. The last traces of acetone and alcohol are eliminated in a scrubber where gases flow against the flow of water coming in from above. In order to obtain pure acetone as a distillate and an effluent that is composed of both water and alcohol, the 3 condensate from the condenser is combined with the effluent from the scrubber and sent to a distillation column. A second distillation column is used to separate the isopropyl alcohol, which contains around 91% alcohol, from the excess water in the effluent. To the reactor it gets recycled. The reaction is carried out at temperatures between 400 and 500C and between 4 and 5 Bars of pressure using zinc oxide as a catalyst. The yield of acetone is around 98%, and 85% to 90% of the isopropyl alcohol is converted through the reactor per pass. For the plant process description given above, which five process variables are likely to be controlled
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