Product design process parameters

The advantages of the LFRT products are offset by requirements to optimize the whole process chain including extruder screw design, processing parameters and mould design, thus needing higher investment and production costs. 

Design a plant to produce chemical X, taking into account uncertain raw materials and product prices, process parameters, raw material availability and product demand, given the forecasts, and determine when the plant should be buUt as well as what expansions are needed ... 

By collecting data on processes and products, the tolerances of product and process parameters (design space) can be determined. According to Q8, design space is the multidimensional combination and interaction of input-variables and process parameters, of which has been shown that they guarantee the quality . 

Product failure analysis is a complex subject. It is though comparatively easy to establish the main reason of product failure. However, when changes in the product are required to avoid the problem, several possibilities exist choice of material, type of grade, product design, mould design, processing parameters and service conditions. Any change in one aspect or property of the material would, on many occasions, lead to compromise on another aspect of the product performance. Hence, careful consideration of different possibilities is required. 

Sometimes the term recipe is used to designate only the raw material amounts and other parameters to be used in manufacturing a batch. Although appropriate for some batch processes, this concept is far too restrictive For others. For some products, the differences from one product to the next are largely physical as opposed to chemical. For such products, the processing instruc tions are especially important. The term formula is more appropriate for the raw material amounts and other parameters, with recipe designating the formula and the processing instruc tions. 

To improve customer satisfaction and business competitiveness, companies need to reduce the levels of non-conformance and attendant failure costs associated with poor product design and development. Attention needs to be focused on the quality and reliability of the design as early as possible in the product development process. This can be achieved by understanding the potential for variability in design parameters and the likely failure consequences in order to reduce the overall risk. The effective use of tools and techniques for designing for quality and reliability can provide this necessary understanding to reduce failure costs. 

Understanding of the technological process and identification of subprocesses are essential for proper ventilation design, especially when designing process ventilation but also in enclosure air technology. The purpose of process description is to identify possible emission sources, occupational areas, the effects of environmental parameters on production, needs for enclosure and ventilation equipment, etc. One purpose is to divide the process into parts such that their inputs and outputs (e.g., process, piping and duct connections, electricity, exposure) to environment can be defined. Parts here can he different departments, and inside them, subprocesses. See Fig. 3.4. 

In addition to the process parameters, there are large numbers of factors that decide the success of an injection molding operation. Mold design, product design, position, and size of gates, type and positioning of runners, etc., are extremely important factors to be taken care of. A detail consideration regarding these factors has been discussed below [213]. 

In summary, the Avada process is an excellent example of process intensification to achieve higher energy efficiency and reduction of waste streams due to the use of a solid acid catalyst. The successful application of supported HP As for the production of ethyl acetate paves the way for future applications of supported HP As in new green processes for the production of other chemicals, fuels and lubricants. Our results also show that application of characterization techniques enables a better understanding of the effects of process parameters on reactivity and the eventual rational design of more active catalysts. 

This chapter contains a discussion of two intermediate level problems in chemical reactor design that indicate how the principles developed in previous chapters are applied in making preliminary design calculations for industrial scale units. The problems considered are the thermal cracking of propane in a tubular reactor and the production of phthalic anhydride in a fixed bed catalytic reactor. Space limitations preclude detailed case studies of these problems. In such studies one would systematically vary all relevant process parameters to arrive at an optimum reactor design. However, sufficient detail is provided within the illustrative problems to indicate the basic principles involved and to make it easy to extend the analysis to studies of other process variables. The conditions employed in these problems are not necessarily those used in current industrial practice, since the data are based on literature values that date back some years. 

Once the four flow rate ratios are selected, two additional constraints are necessary to determine the values of the six design and process parameters required for operating an SMB. In particular, V, t and Qj,j = 1,..., 4 are wanted for the set up of the separation. The volume of the columns is normally a given one, especially if the plant is already in use, or it is selected based on productivity re-... 

There are broadly two uses of chemometrics that interest the process chemist. The first of these is simply data display. It is a truism that the human eye is the best analytical tool, and by displaying multivariate data in a way that can be easily assimilated by eye a number of diagnostic assessments can be made of the state of health of a process, or of reasons for its failure [ 153], a process known as MSPC [154—156]. The key concept in MSPC is the acknowledgement that variability in process quality can arise not just by variation in single process parameters such as temperature, but by subtle combinations of process parameters. This source of product variability would be missed by simple control charts for the individual process parameters. This is also the concept behind the use of experimental design during process development in order to identify such variability in the minimum number of experiments. 

Especially the parameter design step gives the best opportunity to incorporate and/or to increase the quality of a product or process. Therefore the rest of this part concentrates on the parameter design step. 

---