EMPIRICAL PROCESS MODELING

Example Of Empirical Modeling

1. Situation:
  • A PVC manufacturer wanted to increase process throughput by 15 to 20 Percent over what he had.
  • This manufacturer contacted UTI to model the process empirically to determine what process improvements could increase yields by reducing the batching cycle.
  • The manufacturer needed to increase throughput and was limited by time and capital.




Assumptions:
  • An adiabatic process was used for the purpose of modeling
  • The mass of the product is considered infinite and steady state at 125 ºF
  • Delta T is approximately = to Delta T (Log Mean) for Jackets and Baffles
  • U is a constant and is not a function of position or temperature
  • For heat transfer, physical properties of fluid are constant and not a function of temperature
  • Steady state flow conditions exist for both fluids, product and cooling media
  • U, the overall heat transfer for stainless steel is 113 BTU/Hr-Sq ft-ºF
  • The Pfaudler Baffle is a Glass Type 5311, Carbon Steel Coated Baffle
  • The Pfaudler Baffle Surface Area, 75 Sq-ft
  • Specific heat of PVC is 0.3 BTU/lb-ºF
  • Approximate batching Time 8 hours
  • Batching temperature =125 ºF
  • Finished product temperatures 87 ºF


2. Cost for Model Development:
  • $19,000 to develop the model, rent explosion proof, non-destructive flow sensors, create the drawings, develop a list of recommendations and estimate the total installation.
3. Client Benefits:
  • The owner had an 85% level of confidence that the proposed changes would pay for themselves within nine months.
  • The TIC to make all necessary modifications was estimated at $250,000.
  • The equipment was installed for $180,000 and paid for itself within six weeks.






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