Is there automatic control for fine chemical products produced in small batches with multiple varieties? What issues need attention?
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For environmental and safety reasons, many hazardous chemical reactions must be under automatic control. But we are a fine chemical manufacturer that produces small batches of various products. Firstly, our scale is relatively small and production volumes are low, which makes automation costly. Secondly, frequent changes in the product line often require adjustments to the instruments and control parameters on site, and we lack the talent and experience in this area. Thirdly, there are issues related to the selection of instruments; for example, when it comes to level gauges for storage tanks, using differential pressure types can result in inaccurate readings due to changes in the density of the medium, among other problems. Could any colleagues in the fine chemicals industry share their practical production experience?
The last edit to this post was made by Bright sun on 2018-12-19 at 13:34. It seems like there are serious problems: our reaction vessels are quite small, with the largest ones having a capacity of only 3000L. Production takes place in batch mode, and strict requirements exist regarding temperature and pH levels. We’re particularly concerned about delays, as this could lead to the formation of many by-products. We are also exploring the use of microchannel reactors, but the price is too high, and it’s even more difficult to find relevant experience in their use.
Insufficient investment in automation, shortage of talent: L. To ensure environmental protection and safety, investment is certainly required. If one cannot afford imported instruments, at least high-quality domestic brands should be chosen; the accuracy of these instruments is very important. Let’s hire a few good technicians first to make up for it; there’s still a long way to go.
:'(I’ve learned a little; my undergraduate degree was in Process Equipment and Control Engineering, but I mainly focused on static equipment. My knowledge of control systems is limited to positive and negative feedback as well as open-loop and closed-loop control. I have no idea anything about the use of PID, PLCs, or DCS.)
If it’s just because the products are different, with different formulas and different proportions. This issue has been well addressed in terms of automation; many recipes can be stored during programming, and you simply use the one that corresponds to what you are producing. You mentioned factors such as liquid level selection; I’m concerned that changes in density might cause errors. Just choose a method that does not rely on the principle of density, depending on the specific operating conditions. As for the cost, it needs to be calculated based on your scale; I can’t provide you with a specific figure for reference.
There are many things; it’s hard to explain. It’s fine as long as one doesn’t suffer too much loss
It is recommended to entrust a qualified and experienced design firm to take overall responsibility for your technical upgrades. Since it is part of a hazardous chemicals system, what if the instrument chosen by oneself has problems and causes an accident! Following it up can have serious consequences.