Product temperature, controlling

The worker unit is normally mounted with a heating jacket for tempered water on the cylinder and often also equipped with its own built-in water heater and circulation pump for the tempered water. This is advantageous in preventing product buildup on the cylinder wall and allows better product temperature control during the passage through the worker unit. Product temperature increases of 2°C or more due to release of latent heat of crystallization and mechanical work can be observed in the worker imit (3). 

This concept of cycle validation is even more important due to the breakthrough of the ALUS (Automatic Loading Unloading Systems), isolation technologies, and RABS (Restricted Access Biological Systems) which make product temperature control and monitoring very difficult if not almost impossible to handle. 

A typical flow diagram for pentaerythritol production is shown in Figure 2. The main concern in mixing is to avoid loss of temperature control in this exothermic reaction, which can lead to excessive by-product formation and/or reduced yields of pentaerythritol (55,58,59). The reaction time depends on the reaction temperature and may vary from about 0.5 to 4 h at final temperatures of about 65 and 35°C, respectively. The reactor product, neutralized with acetic or formic acid, is then stripped of excess formaldehyde and water to produce a highly concentrated solution of pentaerythritol reaction products. This is then cooled under carefully controlled crystallization conditions so that the crystals can be readily separated from the Hquors by subsequent filtration. 

The reaction occurs at essentially adiabatic conditions with a large temperature rise at the inlet surface of the catalyst. The predominant temperature control is thermal ballast in the form of excess methanol or steam, or both, which is in the feed. If a plant is to produce a product containing 50 to 55% formaldehyde and no more than 1.5% methanol, the amount of steam that can be added is limited, and both excess methanol and steam are needed as ballast. Recycled methanol requited for a 50—55% product is 0.25—0.50 parts per part of fresh methanol (76,77). 

In contrast to the silver process, all of the formaldehyde is made by the exothermic reaction (eq. 23) at essentially atmospheric pressure and at 300—400°C. By proper temperature control, a methanol conversion greater than 99% can be maintained. By-products are carbon monoxide and dimethyl ether, in addition to small amounts of carbon dioxide and formic acid. Overall plant yields are 88—92%. 

The hot gases from the combustor, temperature controlled to 980°C by excess air, are expanded through the gas turbine, driving the air compressor and generating electricity. Sensible heat in the gas turbine exhaust is recovered in a waste heat boiler by generating steam for additional electrical power production. 

Induction heating equipment installations can require significant investment in electric power components as well as the work handling equipment made necessary by the process. These costs can be offset by savings in plant space, reduction in metal loss, precise control of product temperature, and reduced in-process inventory. A typical continuous induction heating line consumes about 360 kW h/t heating carbon steel bars to 1230°C. 

Temperature control is important in the handling and storage of isocyanates. Storage at inappropriate temperatures can cause product discoloration, viscosity increases, and dimerization. Handling personnel should consult the technical data sheets for the recommended storage temperature of the specific isocyanate product. 

Storage tanks, lines, and pumps should be heat traced and insulated to enable product handling. Temperature control is required to prevent product degradation because of color alkan olamines have poor heat transfer properties. Exposure to air will also cause product discoloration. Storage tanks should be nitrogen-padded if low color product is required. 

Catalyst Development. Traditional slurry polypropylene homopolymer processes suffered from formation of excessive amounts of low grade amorphous polymer and catalyst residues. Introduction of catalysts with up to 30-fold higher activity together with better temperature control have almost eliminated these problems (7). Although low reactor volume and available heat-transfer surfaces ultimately limit further productivity increases, these limitations are less restrictive with the introduction of more finely suspended metallocene catalysts and the emergence of industrial gas-phase fluid-bed polymerization processes. 

Fermentation. The term fermentation arose from the misconception that black tea production is a microbial process (73). The conversion of green leaf to black tea was recognized as an oxidative process initiated by tea—enzyme catalysis circa 1901 (74). The process, which starts at the onset of maceration, is allowed to continue under ambient conditions. Leaf temperature is maintained at less than 25—30°C as lower (15—25°C) temperatures improve flavor (75). Temperature control and air diffusion are faciUtated by distributing macerated leaf in layers 5—8 cm deep on the factory floor, but more often on racked trays in a fermentation room maintained at a high rh and at the lowest feasible temperature. Depending on the nature of the leaf, the maceration techniques, the ambient temperature, and the style of tea desired, the fermentation time can vary from 45 min to 3 h. More highly controlled systems depend on the timed conveyance of macerated leaf on mesh belts for forced-air circulation. If the system is enclosed, humidity and temperature control are improved (76). 

Continuous oxidizers are usually operated at a constant temperature (260 °C) and a constant Hquid level with the production rate and product characteristics controlled by air rate and charging rate. 

A typical bourbon fermentation continues for 72 hours at a fermentation temperature within the 31—35°C range. Many fermentation vessels are equipped with agitation and/or cooling coils that facHitate temperature control. Significant increases in yeast numbers occur during the first 30 hours of fermentation. Over 75% of the carbohydrate is consumed and converted to ethanol. Within 48 hours, 95% or more of the ethanol production is complete. 

Solid Sta.te. The stabiHty of neutral calcium hypochlorite is primarily a function of moisture, lime, impurities, and temperature. Product containing - 7% water may lose 2—3% av CI2 during the first year when stored in warehouses without temperature control in moderate climates. Decomposition produces CaCl2, Ca(C102)2, and O2. 

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