Delta Company for Fertilizers and
Chemical Industries
Training Report
Submitted By:
Kareem Mohamed Elarby Hassanin Ali
803089481 – MTE Level 400
Training Supervisor: Mohamed Nabeih Hakem
Training Period: August 29, 2024, − September 28, 2024
Company Overview:
Delta Company for Fertilizers and
Chemical Industries specializes in the
production of nitrogenous fertilizers and
compound fertilizers.
Company Address:
Talkha, Dakahlia
A.
Most important fertilizers and chemical
industry factories in Egypt:
1. Afco Misr Company for the manufacture of phosphate and
biological fertilizers and chemicals
► The company is considered one of the most important fertilizer and
chemical companies in Egypt, as all the products issued by the
company are ISO 9001 certified for quality, and the Egyptian
Standards and Quality Authority, and all products are registered and
under the supervision of the Ministry of Agriculture and the Central
Laboratory for Organic Agriculture.
► Among the most important products offered by the company are fully
soluble potassium sulfate, triple granulated farmer’s superphosphate,
granular monolithic superphosphate, fine Mono superphosphate,
granulated agricultural sulfur, fine agricultural sulfur, and original
soil conditioners.
► The company also provides vegetable and animal compost, mixture
compost, vegetable compost and agricultural gypsum, and it has a wide
reputation in Egypt and the Middle East countries.
2. Shams Fertilizers and Chemicals Company The company is one of
the fertilizer and chemical companies in Egypt affiliated to the
Dakahlia Group, and it is one of the largest groups specialized in
the poultry and agricultural field in Egypt and the Middle East
region.
► The company provides organic fertilizers, including poultry compost,
animal compost, animal compost, poultry compost, regular fertilizers
such as potassium sulfate, urea phosphate, phosphoric acid, compound
elements and microelements, and their various compositions, and
specialized fertilizers, including algae extracts, root stimulants, and
humic acids.
► It provides all the various agricultural pesticides that are used to
eliminate all agricultural pests that harm agricultural crops. The
company is located in 11 Ramo Buildings, ninth floor, Nasr Road, Nasr
City, Cairo.
3. Rocket Fertilizers and Chemicals Company
► Rocket Fertilizers and Chemicals Company specializes in the
manufacture and production of fertilizers, fertilizers and plant growth
regulators with new and advanced technology from the finest
international raw materials, which keep pace with the rapid and
continuous development in the agricultural field by providing a new
level of quality.
► The company is keen to keep pace with production, with new types of
genetically hybrid seeds with high productivity, which require
providing nutrients in an easy-to-absorb form for the plant, and thus
returns to the farmer and investor in the agricultural field high
productivity, while maintaining the economic quality of the crops.
► The company offers the new generation of fertilizers, not depending on
the percentage of nutrients in the fertilizer, but rather in the form in
which the element is found, in a way that facilitates its absorption and
access to the plant through foliar and root spraying, which reduces the
number of treatment times, saves costs, and thus increases the
economic return on investment. in the agricultural field.
4. Fertilizers and chemicals export companies in Egypt.
-
B.
through the diversity of fertilizer and chemical companies in Egypt, as
well as the companies exporting these materials, including the
Egyptian company Methanex, which specializes in methanol
production, is one of the most important companies, in terms of
exports, which amounted to 339.228 million dollars, accounting for
17%. of the total exports of those companies.
Information about delta factor
The Nasr Company for Fertilizers and Chemical Industries was
established in 1946 in Suez and continued to operate until the 1967
aggression. By 1975, a design was made for the urea production
plant (1725 tons / day), including the ammonia production unit
(1200 tons / day), which began operating in 1980. On 1-7-1998, the
Delta Fertilizer Company was established in Talkha, divided from
the Nasr Fertilizer Company.
Table of Contents
1. Introduction
2. Objective
3. Training Topics
3.1 Principles of Industrial Control
3.2 Measurement Devices for Industrial Process Variables
(Pressure, Temperature, Level, Flow)
3.3 Control Valves
3.4 Introduction to Industrial Controllers (e.g., Programmable
Logic Controllers - PLC)
4. Training Program
4.1 First Week: Open Loop and Closed Loop Control Systems
4.2 Second Week: Local and Remote Measuring Devices
4.3 Third Week: Differentiation Between Various Control
Systems (PLC, DCS)
4.4 Fourth Week: Types of Signals (On/Off and Continuous
Signals)
5. Control Systems
5.1 Background
5.2 Open Loop and Closed Loop Control Systems
5.3 Programmable Logic Controllers (PLC) and Distributed
Control Systems (DCS)
6. On-Off Control System
7. Pressure Gauges
7.1 What is a Pressure Gauge
7.2 Types of Pressure Gauges
8. Conclusion
9. List of Symbols and Units
10. References
Time
Comments
1st week
Get to know Open loop and closed loop control
system.
2nd week
Recognize Local and remote measuring devices.
3rd week
Differentiate between various control system, such
as (stand-alone controllers, PLC, DS)
4th week
Learn about different types of signals for variables
in the site (On/Off and continuous signals)
1. Training Program
1st Week: Open Loop and Closed Loop Control Systems
During the first week, we explored the differences between open loop
and closed loop control systems. Figure 1 shows a simple block
diagram of an open loop control system.
2nd Week: Local and Remote Measuring Devices
The second week involved learning about various local and remote
measuring devices used in the industry.
3rd Week: Differentiation Between Various Control Systems
(PLC, DCS)
In the third week, we focused on understanding the differences
between Programmable Logic Controllers (PLC) and Distributed
Control Systems (DCS).
4th Week: Types of Signals (On/Off and Continuous Signals)
The final week covered different types of signals such as On/Off and
continuous signals used in control systems.
2. Introduction
This technical report provides an overview of the training
conducted at Delta Company for Fertilizers and Chemical
Industries. The training focused on the fundamentals of industrial
control systems and practical knowledge in managing various
types of industrial equipment and processes.
3. Objective
The objective of this training was to gain hands-on
experience in control systems and to understand the different
aspects of industrial automation used in chemical industries.
4. Training Topics
► 4.1. Principles of Industrial Control
This section covers the basic principles of industrial control,
including the types of control systems and their applications.
► 4.2. Measurement Devices for Industrial Process Variables
Training included learning about devices used to measure
critical process variables such as pressure, temperature, level,
and flow.
► 4.3. Control Valves
Understanding the role of control valves in managing fluid flow
and pressure in process industries.
► 4.4. Introduction to Industrial Controllers
An overview of industrial controllers, focusing on
Programmable Logic Controllers (PLC), their applications, and
how they are programmed.
5. Control Systems
► 5.1. Background
A control system manages, commands, directs, or regulates the
behavior of other devices or systems using control loops.
► 5.2. Open Loop and Closed Loop Control Systems
Control systems are broadly classified into open loop and closed
loop systems. Figure 2 illustrates a closed loop control system
with negative feedback.
► 5.3. Programmable Logic Controllers (PLC) and Distributed
Control Systems (DCS)
PLCs and DCSs are vital in industrial automation for
controlling various processes. Table 1 compares PLCs and
DCSs based on their features and applications.
► 5.4. On-Off Control System
An on-off control system is a simple type of control system often
used for its simplicity and ease of implementation. Figure 3
depicts a typical on-off control system used in industrial
applications.
The following figure shows the block diagram of negative
feedback closed loop control system.
The error detector produces an error signal, which is the difference
between the input and the feedback signal. This feedback signal is
obtained from the block (feedback elements) by considering the output
of the overall system as an input to this block. Instead of the direct
input, the error signal is applied as an input to a controller. So, the
controller produces an actuating signal which controls the plant. In this
combination, the output of the control system is adjusted automatically
till we get the desired response. Hence, the closed loop control systems
are also called the automatic control systems.
► The differences between the open and the closed loop
control systems are mentioned in the following table.
Open Loop Control Systems
Closed Loop Control Systems
Control action is independent of the
desired output.
Control action is dependent of the
desired output.
The feedback path is not present.
The feedback path is present.
These are also called non-feedback
control systems.
These are also called feedback
control systems.
Easy to design.
Difficult to design.
These are economical.
These are costlier.
Inaccurate.
Accurate.
► Programmable logic controllers (PLC) and Distributed
Control Systems (DCS).
In the world of industrial automation, Programmable logic
controllers (PLC) and Distributed Control Systems (DCS)
are used to control or automate a process or a machine. They
monitor the field signals and operator inputs and make
decisions based on how they are programmed.
PLC stands for “Programmable Logic Controller”
Historically a PLC was in discrete control of manufacturing
processes. The whole discrete logic used to be implemented
with relay circuitry. Most of the inputs and outputs for
discrete control are binary, meaning they have only two
states: On and Off.
► DCS stands for “Distributed Control System”
DCS’s were designed to control processes, not discrete
operations. As such, a large number of the inputs and
outputs are analog like a 4-20mA signal or 0-10V signal.
In Literary meaning, a Distributed Control System (DCS)
refers to a control system usually of a process or
manufacturing system, in which the controller elements are
not central in location (like the brain) but are distributed
throughout the system with each component sub-system
controlled by one or more controllers. Process plants used to
have long series of panel mounted Single Loop Controllers
(Analog/PID controllers).
► PLC vs DCS
With emerging technologies, the difference between PLC and
DCS has become quite marginal. In spite of that here are a
few differences between them.
PROGRAMMABLE LOGIC
CONTROLLERS (PLC)
DISTRIBUTED CONTROL
SYSTEMS (DCS)
Speed of
response
PLCs can respond to a change
within one-tenth of a second.
DCS are slower than PLCs. Typical
respond time of DCS is 30ms.
IO capacity
A PLC is capable of handling a
few hundred IOs. When it comes
to analog IOs, it can handle tens
of them.
A DCS can handle thousands of IOs.
It can handle hundreds or even
thousands of analogs IOs and PID
functions
Logic
development
PLC can programmed be
programmed based on our
application.
DCS comes with built-in control
functions that need to be configured
based on the application.
Redundancy
PLCs can be made redundant
with additional hardware which
makes them more expensive
than DCS.
Redundancy is a default feature of
distributed control systems.
Architecture
PLCs have a simple and flexible
architecture. A PLC system
consists of controllers, IO
modules, HMIs and an
engineering software.
DCS systems are less flexible. They
come with controllers, IO systems,
database servers, engineering and
operating servers.
Application
PLCs are best suited for
dedicated applications that
changes less often.
DCS is suitable for complex
processes that require advanced
process control capability.
Cost
Less expensive.
More expensive.
6. On-off control system
- In an industrial plant, a closed-loop control system has
the role of keeping a measured physical signal to a
predefined value (setpoint). The physical signal, also
called controlled variable, can be of any kind, electrical
(voltage, current, power), mechanical (position, speed, force,
torque), hydraulic (pressure, flow) or thermal (temperature).
The difference between the controlled variable (measured)
and the predefined value is called error.
- The input of the controller is the error, and the controller
output is an actuation signal which is sent to an actuator.
The controlled variable is further measured with a sensor
and the information is fed back to the controller.
Closed loop (feedback) control system
- The difference between the setpoint and the plant output
(measured) occurs because of the disturbances which affect
the plant (process). The role of the controller is to reject
these disturbances and keep the plant output (controlled
variable) to the predefined value (setpoint).
- The ways in which the controller reacts to the error are
called control laws or control modes. In industrial
applications there are several control laws used, most of
them being on-off control, PID control or other more
advanced laws (fuzzy, neuro-fuzzy, optimal, etc.).
- The on-off control is the simplest form of a controller, which
switches ON when the error is positive and switches OFF
when the error is zero or negative. An on-off controller
doesn’t have intermediate states but only fully ON or fully
OFF states. Due to the switching logic, an on-off controller is
often called a bang-bang controller or a two-step controller.
- Regardless of the size of the error, the output of the on-off
controller can only be fully ON or fully OFF, it is not
proportional with the error.
- Let’s take as an example the temperature control of an
industrial oven. The temperature inside the oven is
measured with a sensor and feed back to the controller.
Based on the error (difference between setpoint temperature
and measured temperature), the heating elements are
turned ON or OFF by the controller. There are no
intermediate values of the heating element, they are fully
ON or fully OFF.
7. Pressure Gauges
7.1. What is a Pressure Gauge?
The devices used for measuring pressure are called pressure
gauges. Gauge pressure is the pressure relative to
atmospheric pressure. For pressures above atmospheric
pressure, gauge pressure is positive, and for pressures below
atmospheric pressure, gauge pressure is negative. These
devices are also known as pressure meters or vacuum
gauges. A manometer is a device that uses the surface area
and weight of a liquid column to measure and indicate
pressure. Most gauges calculate the pressure relative to
atmospheric pressure as the zero point, which is why this
form of reading is known as gauge pressure. Pressure gauges
can be analog or digital.
7.2. Types of Pressure Gauges
Pressure gauges are designed depending on the usability
and purpose, whether for commercial or industrial purposes.
Some common types of pressure gauges include Bourdon
Tube Pressure Gauge, Diaphragm Pressure Gauge, Capsule
Pressure Gauge, Absolute Pressure Gauge, Differential
Pressure Gauge, Bellows Pressure Gauge, Manometer
Pressure Gauge, Piezometer Pressure Gauge.
8. Conclusion
The training at Delta Company was instrumental in
enhancing my understanding of industrial control systems and
their applications in real-world scenarios.
9. List of Symbols and Units
Symbol
Unit
Description
mA
Milliampere
Electric current
V
Volt
Electric potential
°C
Degree Celsius
Temperature
psi
Pounds per square inch
Pressure
P
Pascal
Pressure at any point
Pa
Pascal
Atmospheric pressure
ρ
kg/m³
Density of the fluid
g
m/s²
Acceleration due to gravity
h
m
Height of the fluid column
10. References
► Ogata, K. (2010). Modern Control Engineering. Prentice
Hall.
► Johnson, C. D. (2006). Process Control Instrumentation
Technology. Pearson Education.
► Bolton, W. (2015). Programmable Logic Controllers. Newnes.