Processes and Process Variables

A process is any operation or series of operations by which a particular objective is accomplished. In this textbook, we address those operations that cause a physical or chemical change in a substance or mixture of substances. The material that enters a process is referred to as the input or feed, and that which leaves is the output or product. It is common for processes to consist of multiple steps, each of which is carried out in a process unit, and each process unit has associated with it a set of input and output process streams. 

In this chapter we present definitions, illustrative measurement techniques, and methods of calculating variables that characterize the operation of processes and individual process units. In later chapters, we discuss how you can use the measured values of some of these variables to calculate process-related quantities that cannot be measured directly but must be known before the process can be fully designed or evaluated. 

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Dutyhoiders should adopt and implement management procedures for planning and control of all changes in plant, processes and process variables, materials, equipment, procedures, software, design or external circumstances which are capable of affecting the control of major accident hazards. 

Weathering and transportation is followed by the sedimentation of material. The depositional environment can be defined as an area with a typical set of physical, chemical and biological processes which result in a specific type of rock. The characteristics of the resulting sediment package are dependent on the intensity and duration of these processes. The physical, chemical, biological and geomorphic variables... 

In practice, each CSF is a Slater determinant of molecular orbitals, which are divided into three types inactive (doubly occupied), virtual (unoccupied), and active (variable occupancy). The active orbitals are used to build up the various CSFs, and so introduce flexibility into the wave function by including configurations that can describe different situations. Approximate electronic-state wave functions are then provided by the eigenfunctions of the electronic Flamiltonian in the CSF basis. This contrasts to standard FIF theory in which only a single determinant is used, without active orbitals. The use of CSFs, gives the MCSCF wave function a structure that can be interpreted using chemical pictures of electronic configurations [229]. An interpretation in terms of valence bond sti uctures has also been developed, which is very useful for description of a chemical process (see the appendix in [230] and references cited therein). 

Patent databases are therefore integrated databases because facts, text, tables, graphics, and structures are combined. In patents that include chemical aspects (mostly synthesis or processing), the chemical compounds are often represented by Markush structures (see Chapter 2, Section 2.7.1). These generic structures cover many compound families in a very compact maimer. A Markush structure has a core structure diagram with specific atoms and with variable parts (R-groups), which are defined in a text caption. The retrieval of chemical compounds from Markush structures is a complicated task that is not yet solved completely satisfactorily. 

Under constant pattern conditions the LUB is independent of column length although, of course, it depends on other process variables. The procedure is therefore to determine the LUB in a small laboratory or pilot-scale column packed with the same adsorbent and operated under the same flow conditions. The length of column needed can then be found simply by adding the LUB to the length calculated from equiUbrium considerations, assuming a shock concentration front. 

Kuhni contacters (Eig. 15e) have gained considerable commercial application. The principal features are the use of a shrouded impeller to promote radial discharge within the compartments, and a variable hole arrangement to allow flexibility of design for different process applications. Columns up to 5 m in diameter have been constmcted (176). Description and design criteria for Kuhni extraction columns have been reported (177,178). 

The air jet textured yam process is based on overfeeding a yam into a turbulent air jet so that the excess length forms into loops that are trapped in the yam stmcture. The air flow is unheated, turbulent, and asymmetrically impinges the yam. The process includes a heat stabilization zone. Key process variables include texturing speed, air pressure, percentage overfeed, filament linear density, air flow, spin finish, and fiber modulus (100). The loops create visual and tactile aesthetics similar to false twist textured and staple spun yams. 

The properties that are achieved in commercial stmctural foams (density >0.3 g/cm ) are shown in Table 3. Because these values depend on several stmctural and process variables, they can be used only as general guidelines of mechanical properties from these products. Specific properties must be deterrnined on the particular part to be produced. A good engineering guide has been pubHshed (103). 

Various processes can be used to produce energy or gaseous, liquid, and solid fuels from biomass and wastes. In addition, chemicals can be produced by a wide range of processing techniques. The following Hst summarizes the principal feed, process, and product variables considered in developing a synfuel-from-biomass process. 

Combustion. Coal combustion, not being in the strictest sense a process for the generation of gaseous synfuels, is nevertheless an important use of coal as a source of gaseous fuels. Coal combustion, an old art and probably the oldest known use of this fossil fuel, is an accumulation of complex chemical and physical phenomena. The complexity of coal itself and the variable process parameters all contribute to the overall process (8,10,47—50) (see also COLffiUSTION SCIENCE AND technology). 

Process variables also play a significant part in determination of surface finish. For example, the higher the current density, generally the smoother the finish on the workpiece surface. Tests using nickel machined in HCl solution show that the surface finish improves from an etched to a poHshed appearance when the current density is increased from ca 8 to 19 A/cm and the flow velocity is held constant. A similar effect is achieved when the electrolyte velocity is increased. Bright smooth finishes are obtained over the main machining zone using both NaCl and NaNO electrolyte solutions and current densities of 45-75 A/cm. ... 

Process variables that must be controlled include the power level, pressure, and flow of the arc gases, and the rate of flow of powder and carrier gas. The spray gun position and gun to substrate distance are usually preset. Substrate temperature can be controlled by preheating and by limiting temperature increase during spraying by periodic intermptions of the spray. 

Siace nitroarenes are reported to be catalyst poisons (18), the concentration of DNT ia the reaction medium is kept as low as is practical with regard to production goals and catalyst usage. The pubHshed kinetic studies are of Htde iadustrial value siace they describe batch processes with high DNT catalyst ratios (18—21). The effects of important process variables, such as temperature and pressure, can only be iaferred from descriptions ia the patent Hterature. 

Because of the time constants and dynamics associated with the top level s control and manipulated variables, setpoints are usually ramped incrementally to their new values in a manner such that the process is not disturbed and the proximity to constraints can be periodically checked before the next increment is made. 

Process Measurements. The most commonly measured process variables are pressures, flows, levels, and temperatures (see Flow LffiASURELffiNT Liquid-levell asurel nt PressureLffiASURELffiNT Temperaturel asurel nt). When appropriate, other physical properties, chemical properties, and chemical compositions are also measured. The selection of the proper instmmentation for a particular appHcation is dependent on factors such as the type and nature of the fluid or soHd involved relevant process conditions rangeabiHty, accuracy, and repeatabiHty requited response time installed cost and maintainabiHty and reHabiHty. Various handbooks are available that can assist in selecting sensors (qv) for particular appHcations (14—16). 

Signal Transmission and Conditioning. A wide variety of physical and chemical phenomena are used to measure the many process variables required to characteri2e the state of a process. Because most processes are operated from a control house, these values must be available there. Hence, the measurements are usually transduced to an electronic form, most often 4 to 20 m A, and then transmitted to the control house or to a remote terminal unit and then to the control house (see Fig. 6). Wherever transmission of these signals takes place in twisted pairs, it is especially important that proper care is taken so that these measurement signals are not cormpted owing to ground currents, interference from other electrical equipment and... 

Many misconceptions exist about cascade control loops and their purpose. For example, many engineers specify a level-flow cascade for every level control situation. However, if the level controller is tightly tuned, the out-flow bounces around as does the level, regardless of whether the level controller output goes direcdy to a valve or to the setpoint of a flow controller. The secondary controller does not, in itself, smooth the outflow. In fact, the flow controller may actually cause control difficulties because it adds another time constant to the primary control loop, makes the proper functioning of the primary control loop dependent on two process variables rather than one, and requites two properly tuned controllers rather than one to function properly. However, as pointed out previously, the flow controller compensates for the effect of the upstream and downstream pressure variations and, in that respect, improves the performance of the primary control loop. Therefore, such a level-flow cascade may often be justified, but not for the smoothing of out-flow. 

Constraint control strategies can be classified as steady-state or dynamic. In the steady-state approach, the process dynamics are assumed to be much faster than the frequency with which the constraint control appHcation makes its control adjustments. The variables characterizing the proximity to the constraints, called the constraint variables, are usually monitored on a more frequent basis than actual control actions are made. A steady-state constraint appHcation increases (or decreases) a manipulated variable by a fixed amount, the value of which is determined to be safe based on an analysis of the proximity to relevant constraints. Once the appHcation has taken the control action toward or away from the constraint, it waits for the effect of the control action to work through the lower control levels and the process before taking another control step. Usually these steady-state constraint controls are implemented to move away from the active constraint at a faster rate than they do toward the constraint. The main advantage of the steady-state approach is that it is predictable and relatively straightforward to implement. Its major drawback is that, because it does not account for the dynamics of the constraint and manipulated variables, a conservative estimate must be taken in how close and how quickly the operation is moved toward the active constraints. 

Grinder Variables. The quaUty of pulp depends on wood species, moisture content, and grinder variables such as peripheral stone speed, grit size and number per unit area, and pattern on the stone surface. Process variables that affect pulp quaUty include grinding pressure pit consistency, ie, consistency in the space immediately below the grinder (2—6%) and temperature (40—80°C). The combination of moisture and raised temperature tends to soften the lignin. 

The three streams and associated variables of the RO membrane process are shown in Figure 2b the feed the product stream, called the permeate and the concentrated reject stream, called the concentrate or retentate. The water flow through the membrane is reported in terms of water flux, J. ... 

Factors affecting RO membrane separations and water flux include feed variables such as solute concentration, temperature, pH, and pretreatment requirements membrane variables such as polymer type, module geometry, and module arrangement and process variables such as feed flow rate, operating time and pressure, and water recovery. 

To solve a flow problem or characterize a given fluid, an instmment must be carefully selected. Many commercial viscometers are available with a variety of geometries for wide viscosity ranges and shear rates (10,21,49). Rarely is it necessary to constmct an instmment. However, in choosing a commercial viscometer a number of criteria must be considered. Of great importance is the nature of the material to be tested, its viscosity, its elasticity, the temperature dependence of its viscosity, and other variables. The degree of accuracy and precision required, and whether the measurements are for quaUty control or research, must be considered. The viscometer must be matched to the materials and processes of interest otherwise, the results may be misleading. 

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