Distillation Plant Automation

Scope of Work

The project covered the full automation of the plant’s distillation process from raw material input to the final production of refined fuels. Key deliverables included:

• Designing and supplying a complete automation control panel.
• Installation of Control Center Monitoring Room.
• Integration of CompactLogix PLC and full SCADA design using FactoryTalk View.
• Ensuring real-time process monitoring and control for all distillation phases.

Technologies & Tools Used

Challenges Faced

One of the major technical hurdles was precisely controlling the temperature levels during the distillation process. Given that the raw input was a mixed oil compound, each refined product (gasoline, kerosene, diesel) required unique temperature thresholds for proper separation.

If the temperature was not tightly controlled, it could lead to significant product loss or contamination between oil grades.

Solutions Provided

• A cascade PID loop strategy was implemented to maintain accurate and stable temperature profiles at each stage.
• The entire distillation process was automated, requiring minimal operator interaction.
• A "one-touch" start process allowed the client to initiate the full sequence by simply opening a valve—after which the system controlled the rest via PLC & SCADA integration.

Results & Benefits

Post-implementation, the client reported:

• 2x to 4x improvement in production quality and yield (depending on raw material composition).
• Significantly reduced manual intervention and error rates.
• Enhanced safety, consistency, and operational efficiency.

This project marks a significant step for Aqua Refinery Limited in its journey toward digital transformation and Industry 4.0 compliance.

Engineer’s Role

• Complete project design & implementation planning.
• PLC hardware configuration and programming.
• SCADA interface development and client training.
• On-site commissioning and performance testing.