During the production process, how does everyone handle issues that are identified by the central control system?
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As the title suggests, while working on the process control, I found that the reaction of the materials did not meet the required standards. In our plant’s synthesis process, since it involves reactions under high temperature and pressure, sampling and analysis can only be carried out after the reaction is complete and the materials are transferred. Under normal conditions, the amount of unreacted material is less than 3%, but occasionally it does exceed this limit. This results in a low concentration of the material during distillation. Moreover, we use an intermediate tank in our distillation process; all the materials from several tanks are first sent to this intermediate tank before proceeding with continuous distillation, which in turn affects the processing of the materials in the other tanks Although products with low content can also be sold, their price is much lower. Mainly, during the material transfer process in our synthesis process, samples are taken for quality control; as a result, it’s not possible to continue synthesizing this batch of material. Moreover, these materials cannot be discarded either. So I would like to ask everyone how such situations are controlled? ?
Is there no one? Everyone, don’t be conservative. . .
This topic is suitable for discussion in the production area
Based on the production status of qualified materials, the process parameters for each reaction step are determined and strictly enforced; the control of the quality of intermediate materials is primarily achieved by monitoring parameters such as feed volume, pressure, temperature, and reflux ratio； Also, is it possible to take samples before distillation? Relevant data should be analyzed by comparing it with the conditions of the material ；
This is a typical post-mortem autopsy, right? What kind of reaction did P LZ show? Are there no control parameters? Can’t make adjustments during the production process?
Personally, I think it’s necessary to optimize the system, improve process control, and ensure a high quality rate
I’m working at a chemical company now, and I’ve encountered similar problems. Since the product is relatively new, there are no highly accurate and reliable control parameters; currently, control is carried out based on empirical values. So what Haiyou mentioned earlier about systematization and dataization simply cannot be achieved. Our main solution at the moment is to increase the amount of wealth generated, while trying to keep the process conditions under control; in other words, we sacrifice energy and processing time in order to achieve higher quality and maximize profits. It is hoped that, as experience accumulates over time, a set of theoretical data can be developed to guide production. I wonder if there are any other more effective methods. . .