Loss of production

Production time lost through the need to clean a heat exchanger can never be recovered and it could in certain situations, mean the difference between profit and loss. 

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The theory of sublimation, t.e. the direct conversion from the vapour to the sohd state without the intermediate formation of the liquid state, has been discussed in Section 1,19. The number of compounds which can be purified by sublimation under normal pressure is comparatively small (these include naphthalene, anthracene, benzoic acid, hexachloroethane, camphor, and the quinones). The process does, in general, yield products of high purity, but considerable loss of product may occur. 

Note 1. Washing, even with concentrated MHi,Cl, gives a considerable loss of product (especially in the case R = H). 

Yields of greater than 60% are obtained (46). This method has been used for the commercial production of OF2 (8). The NaOH concentration, however, must be kept low to avoid the loss of product by a secondary reaction ... 

Without proper control of hazards, a sequence of events (scenario) occurs which results ia an accident. A hazard is defined as anything which could result ia an accident, ie, an unplaimed sequence of events which results ia iajury or loss of life, damage to the environment, loss of capital equipment, or loss of production or inventory. 

For the asymmetric membranes, progressive yield can cause a loss of production rate due to compaction of the matrix in a prolonged operation. The pressure at which hoUow-fiber compaction is initiated, P, can be approximated ... 

When low boiling ingredients such as ethylene glycol are used, a special provision in the form of a partial condenser is needed to return them to the reactor. Otherwise, not only is the balance of the reactants upset and the raw material cost of the resin increased, but also they become part of the pollutant in the waste water and incur additional water treatment costs. Usually, a vertical reflux condenser or a packed column is used as the partial condenser, which is installed between the reactor and the overhead total condenser, as shown in Figure 3. The temperature in the partial condenser is monitored and maintained to effect a fractionation between water, which is to pass through, and the glycol or other materials, which are to be condensed and returned to the reactor. If the fractionation is poor, and water vapor is also condensed and returned, the reaction is retarded and there is a loss of productivity. As the reaction proceeds toward completion, water evolution slows down, and most of the glycol has combined into the resin stmcture. The temperature in the partial condenser may then be raised to faciUtate the removal of water vapor. 

Coccidiosis is a proto2oal disease of the intestinal tract of animals that leads to severe loss of productivity and death. The development and widespread use of anticoccidials has revolutionized the poultry industry. The estimated world market for anticoccidial agents in 1989 was 425 million and this was dominated by the polyether ionophore antibiotics monensin, salinomycin [53003-10-4], n imsm [55134-13-9], la.s9locid, and maduramicin [84878-61-5] (26). 

Sterile aqueous D-sorbitol solutions are fermented with y cetobacter subo >gichns in the presence of large amounts of air to complete the microbiological oxidation. The L-sorbose is isolated by crystallisation, filtration, and drying. Various methods for the fermentation of D-sorbitol have been reviewed (60). A.cetobacter suboyydans is the organism of choice as it gives L-sorbose in >90% yield (61). Large-scale fermentations can be carried out in either batch or continuous modes. In either case, stefihty is important to prevent contamination, with subsequent loss of product. 

There are two general temperature poHcies increasing the temperature over time to compensate for loss of catalyst activity, or operating at the maximum allowable temperature. These temperature approaches tend to maximize destmction, yet may also lead to loss of product selectivity. Selectivity typically decreases with increasing temperature faster deactivation and increased costs for reactor materials, fabrication, and temperature controls. 

In a service in which sudden temperature change would cause upset and loss of product, the induced-draft unit gives more protection in that only a fraction of the surface (as compared with the forced-draft unit) is ejmosed to rainfall, sleet, or snow... 

Despite the use of explosion-pressure-resistant equipment for the full explosion pressure or other design measures outlined later, everything possible must be done to prevent effective ignition sources, because loss of product and interruption of production are equally undesirable. 

For further purification the material may be recrystallized from hot water, or dissolved in alkali and reprecipitated, or distilled under reduced pressure or sublimed. Each of these operations involves considerable loss of product, either through solubility or through decomposition by heat. The best-appearing product is obtained by distillation under reduced pressure. The crude acid is distilled from a Claisen flask with a delivery tube set low in order that the acid need not be heated much above the boiling j)oint. The product boiling at i4i-i44°/20 mm. is ])ure wliitc and melts at 125-132° (Note 8). The yield of distilled acid is about 75-85 per cent of the weight of the crude acid. 

Larger steam turbine or bootstrap required Expander and generator part of process Addition of expander requires prior planning Induction M/G decreases power factor Loss of production on loss of generator or expander... 

Too little maintenance results in unexpected failures and consequential major losses of production and/or customers (Figure 7-1). This impractical approach is termed reactive strategy and should be avoided on all important machinery. Optimum maintenance strategy balances reasonable costs with maximum possible availability and reliability. The two main maintenance strategies employed by companies today are labelled predictive strategy and preventive strategy. These are part of a balanced approach as shown in Figure 7-2. 

Since 1-ethoxy-1-butyne is very volatile, extreme care should be taken during the work-up to minimize loss of product due to evaporation. Extractions especially should be accompanied by careful and frequent venting of the separatory funnel to prevent excessive pressure. 

While loss of product may not be considered a quality matter, it is if the product is customer property or if it prevents you from meeting your customer requirements. Delivery... 

If the equilibrium were established rapidly, reduction of the free ketone as it formed would result in a substantial loss of product. Lithium enolates are more covalent in character than are those of sodium and potassium and consequently are the least basic of the group. This lower thermodynamic basicity appears to be paralleled by a lower kinetic basicity several workers have shown that lithium enolates are weaker bases in the kinetic sense than are those of sodium and potassium." As noted earlier, conjugated enones... 

The costs of a wrong decision are loss of production, on the one hand, and failure to respond to a real emergency on the other. In order to improve his or her decision basis, the control room worker will usually dispatch others to the source of the emergency signal to declare whether it is spurious (false alarm) or whether it is real, but it is containable without need for depressurizing. This takes up valuable time, during which the situation could escalate dangerously. 

The Chemical Process Industry (CPI) uses various quantitative and qualitative techniques to assess the reliability and risk of process equipment, process systems, and chemical manufacturing operations. These techniques identify the interactions of equipment, systems, and persons that have potentially undesirable consequences. In the case of reliability analyses, the undesirable consequences (e.g., plant shutdown, excessive downtime, or production of off-specification product) are those incidents which reduce system profitability through loss of production and increased maintenance costs. In the case of risk analyses, the primary concerns are human injuries, environmental impacts, and system damage caused by occurrence of fires, explosions, toxic material releases, and related hazards. Quantification of risk in terms of the severity of the consequences and the likelihood of occurrence provides the manager of the system with an important decisionmaking tool. By using the results of a quantitative risk analysis, we are better able to answer such questions as, Which of several candidate systems poses the least risk Are risk reduction modifications necessary and What modifications would be most effective in reducing risk ... 

It follows that any maintenance program introduced for specific plant and equipment must be designed so that all maintenance costs are recorded. This would then be taken into consideration when the life-cycle cost of the item is assessed, as it should be added to the loss of production if this has occurred due to any maintenance malfunction. Care must be taken when presenting the life-cycle cost to ensure that all elements within the cost cycle have been effective. 

The result of ineffective maintenance management represents a loss of more than 60 billion dollars each year. Perhaps more important is the fact that our ineffective management of maintenance dramatically impacts our ability to manufacture quality products that are competitive in the world market. The loss of production time and product quality that results from poor or inadequate maintenance management has had a dramatic impact on our ability to compete with Japan and other countries that have implemented more advanced manufacturing and maintenance management philosophies. 

The principal economic implications of corrosion of a plant are the initial cost of construction, the cost of maintenance and replacement, and the loss of production through unplanned shutdowns. The initial cost of the plant is influenced by material selection, and a choice of material that is more corrosion resistant than is necessary for the safe operation of the plant over its design life is a very expensive error. This cost involves initial outlay of money, and plants have been built which could never be profitable because of the inappropriate materials selection. 

Sudden or catastrophic failure of plant through corrosion can result in the loss of product at high velocity from a failed reactor vessel, high-energy steam from steam... 

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