Why didn’t quadrupling the size of the distillation column unit yield the expected results? Please give me some advice
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It turns out that the factory originally had a small production line consisting of 4 distillation towers and evaporators. To increase production, this line was expanded by a factor of 4. Currently, each of the 4 towers is 27 meters tall and is equipped with thin-film evaporators; the vacuum level is the same as that in the old line. However, the purity of the product no longer increases over time, remaining within the range of 93–94%. Please give me some advice! Kneel in gratitude
Scaling up in industry is not a simple 1+1 affair; you should have the design team conduct simulations before making such modifications!
The device is scaled up, but not in a proportional manner; sometimes a exponential scale factor is used. For example, if the diameter of the tower is increased by four times, then the gas velocity in the tower increases by 16 times. As a result, the number of theoretical plates required also increases by that same factor, rather than by four times
This post was last edited by CHANGBAISHI on 2020-5-29 07:04. Apart from the factors mentioned above, could it be related to the distribution of materials? For example, an uneven distribution of materials in the upward-moving gas or downward-flowing fluid? Since such a high purity can be achieved, it’s likely not something that ordinary people can accomplish.
This post was last edited by Qingcheng Jun on 2020-5-29 09:44. If it has gone through proper design, approval, and construction processes, it is normal for adjustments to fail during the initial trial production phase; professional personnel are needed to figure things out on site. If it’s someone who decides to scale it up on their own, a 27-meter-tall tower – would they just go ahead and do it without even having a design firm do the calculations? Is it possible to pass the safety supervision and environmental protection inspections without going through a design institute? We can design our own experimental distillation column with a diameter of 100 mm and a height of 6 M, order it from a equipment manufacturer, and still manage to stay within acceptable limits; 27 meters seems like an excessive amount. How much longer can those who have to cross rivers by feeling their way around the rocks manage to cover the sky with one hand?
I wonder if multiplying by 4 here means enlarging both the diameter and height of the tower? Even if the tower diameter is increased by 4 times, the processing capacity doesn’t increase by 4 times either; it’s not proportional
Could it be that the speed of the evaporator is not sufficient?
It needs to be calculated, and after that, control operations must be carried out. It’s not just trial and error.
Your description is too brief; to resolve the issue, a more detailed description is needed, such as the dimensions of the original processing equipment, the purity of the product, and the dimensions of the new equipment. Simply multiplying everything by 4 isn’t enough to identify the problem – this may require the help of professionals. You can contact me
Bro, the last time I saw you talk about issues with vacuum pipelines, I suspect that your workshop was set up by you yourself, and many of its aspects don’t meet basic design requirements. Process-related matters need to be carefully considered – this is far more important than problems with guardrails, pipes, or equipment. If there are issues with the process, it’s very difficult to deal with them