This paper presents how nonlinear PID control algorithms can be applied on chemical processes for a more stable operation and perfect automation. A pass balance controller is designed to balance the exiting temperatures of a heater and a heat exchange network. The proposed controller has gain-varying integral action and deals with the operational constraints in an efficient manner. Also, the use of a PID gap controller is proposed to maximize energy saving and operation stability and to minimize operator intervention in operation of air fan coolers. The proposed controller adjusts the opening of a louver automatically in such a way that it keeps the air fan pitch position within the desired range. All these nonlinear PID controllers have been implemented on the distributed control system (DCS) for good reliability and operability. Operator acceptance was very high and the implemented controllers have shown good performance and high service factor still now on. The proposed methodology can be directly applied to similar processes without any modification.