Plastics Process Analysis Instrumentation And Control

This book focuses on plastics process analysis, instrumentation for modern manufacturing in the plastics industry. Process analysis is the starting point since plastics processing is different from processing of metals, ceramics, and other materials. Plastics materials show unique behavior in terms of heat transfer, fluid flow, viscoelastic behavior, and a dependence of the previous time, temperature and shear history which determines how the material responds during processing and its end use. Many of the manufacturing processes are continuous or cyclical in nature. The systems are flow systems in which the process variables, such as time, temperature, position, melt and hydraulic pressure, must be controlled to achieve a satisfactory product which is typically specified by critical dimensions and physical properties which vary with the processing conditions. Instrumentation has to be selected so that it survives the harsh manufacturing environment of high pressures, temperatures and shear rates, and yet it has to have a fast response to measure the process dynamics. At many times the measurements have to be in a non-contact mode so as not to disturb the melt or the finished product. Plastics resins are reactive systems. The resins will degrade if the process conditions are not controlled. Analysis of the process allows one to strategize how to minimize degradation and optimize end-use properties.

This is the first in-depth presentation in book form of current analytical methods for optimal design, selection and evaluation of instrumentation for process plants. The presentation is clear, concise and systematic-providing process engineers with a valuable tool for improving quality, costs, safety, loss prevention, and production accounting. From Chapter 1 Introduction "Instrumentation is needed in process plants to obtain data that are essential to perform several activities. Among the most important are control, the assessment of the quality of products, production accounting... and the detection of failures related to safety. In addition, certain parameters than cannot be measured directly, such as heat exchanger, fouling or column deficiencies, are of interest. Finally, new techniques, such as on-line optimization, require the construction of reliable computer models for which the estimation of process parameters is essential. "This book concentrates on the tasks of determining the optimal set of measured variables and selecting the accuracy and reliability of the corresponding instruments. The goal is to obtain sufficiency accurate and reliable estimates of variables of interest while filtering bad data due to possible instrument malfunction. An additional goal is to observe and diagnose single and multiple process faults." From the Preface "There is a vast amount of literature devoted to the selection and good maintenance of instruments. This literature covers the selection of the right instrument for a particular range and system, but only after the desired accuracy and reliability of measurement have been established. Little has been written on how to systematically determine the right accuracy and reliability needed when selecting an instrument, much less how much redundancy is needed for a particular system. The key variables that needed estimation come from control requirements, as well as monitoring needs for safety, quality control and production accounting. These are the starting points of the design methodology. This book concentrates on determining the optimal accuracy and reliability of instruments and their location. To determine this, certain desired properties of the system of instruments are used as constraints while the cost is minimized. These properties, among others are variable observability, system reliability and precision of certain variables. "This book is not a textbook. Rather it is intended to be an organized collection of the most relevant work in this area.... It has been written with the intention of making it readable by engineers with some background in linear algebra, mathematical optimization and graph theory. It is organized so that the complexity of the sensor network design is addressed step by step." The information in this new book serves the needs of chemical and other process engineers involved in instrumentation and control, maintenance, plant operations, process design, process development, quality control, safety, and loss prevention. Illustrations and Tables The text is supplemented with more than 100 flow charts, diagrams and other schematics that illustrate procedures, systems and instrumentation. More than 70 tables provide useful reference data. The Author Dr. Miguel J. Bagajewicz brings to this new book his extensive experience in design, data management, teaching and writing in the area of process engineering. He received his M.S. and Ph.D. in Chemical Engineering from the California Institute of Technology. He is presently Associate Professor, School of Chemical Engineering and Materials Science, and Director, Center for Engineering Optimization at the University of Oklahoma. He is the author or co-author of more than 100 journal articles, conference presentations, and reports, and the author of articles on data reconciliation and sensor location in the Instrument Engineers' Handbook, fourth edition. He is a member of the American Institute of Chemical Engineers (AIChE), and on the executive committee of the Central Oklahoma Chapter.

This comprehensive book provides guidelines for maximizing plastics proc essing efficiency in the manufacture of all types of products, using all types of plastics. A practical approach is employed to present fundamental, yet comprehensive, coverage of processing concepts. The information and data presented by the many tables and figures interrelate the different variables that affect injection molding, extrusion, blow molding, thermoforming, compression molding, reinforced plastics molding, rotational molding, re action injection molding, coining, casting, and other processes. The text presents a great number of problems pertaining to different phases of processing. Solutions are provided that will meet product per formance requirements at the lowest cost. Many of the processing variables and their behaviors in the different processes are the same, as they all in volve basic conditions of temperature, time, and pressure. The book begins with information applicable to all processes, on topics such as melt soft ening flow and controls; all processes fit into an overall scheme that re quires the interaction and proper control of systems. Individual processes are reviewed to show the effects of changing different variables to meet the goal of zero defects. The content is arranged to provide a natural progres sion from simple to complex situations, which range from control of a sin gle manual machine to simulation of sophisticated computerized processes that interface with many different processing functions.

Quality Management in Plastics Processing provides a structured approach to the techniques of quality management, also covering topics of relevance to plastics processors. The book’s focus isn’t just on implementation of formal quality systems, such as ISO 9001, but about real world, practical guidance in establishing good quality management. Ultimately, improved quality management delivers better products, higher customer satisfaction, increased sales, and reduced operation costs. The book helps practitioners who are wondering how to begin implementing quality management techniques in their business focus on key management and technical issues, including raw materials, processing, and operations. It is a roadmap for all company operations, from people, product design, sales/marketing, and production – all of which are impacted by, and involved in, the implementation of an effective quality management system. Readers in the plastics processing industry will find this comprehensive book to be a valuable resource. Helps readers deliver better products, higher customer satisfaction, and increased profits with easily applicable guidance for the plastics industry Provides engineers and technical personnel with the tools they need to start a process of continuous improvement in their company Presents practical guidance to help plastics processing companies organize, stimulate, and complete effective quality improvement projects

Analytical Instrumentation examines analyzers for detecting pollutants and other hazardous matter, including carbon monoxide, chlorine, fluoride, hydrogen sulfide, mercury, and phosphorous. Also covers selection, application, and sampling procedures. Béla G. Lipták speaks on Post-Oil Energy Technology on the AT&T Tech Channel.

POLYMERS AND ADDITVES IN EXTREME ENVIRONMENTS Uniquely catalogs polymers and additives for uses in extreme applications such as in high or low pressure, high or low temperature, deep water and other special applications. The book includes chapters on aqueous environments including polymeric membranes for water purification and wastewater treatment; extreme pressure environments such as oils and lubricants for combustion engines as well as materials used for deep drilling such as surfactants, scale inhibitors, foaming agents, defoamers, propellants, fracturing fluids; extreme temperatures is subdivided in high and low temperature applications including gasketing materials, fuel tank sealants, expulsion bladders, fuel cell materials, and on the other hand, cold weather articles and thermoregulatory textiles; electrical applications include solar cell devices, triboelectric generators, fuel cell applications, electrochromic materials and batteries; medical applications include polymers for contact lenses, materials for tissue engineering, sophisticated drug delivery systems; aerospace applications include outer space applications such as low temperature and pressure, also cosmic rays, outgassing, and atomic erosion, as well as materials for electrostactic dissipative coatings and space suits; a final chapter detailing materials that are used in other extreme environments, such as adhesives, and polymeric concrete materials. Audience Materials and polymer scientists working in manufacturing and plastics, civil and mechanical engineers in various industries such as automotive, aircraft, space, marine and shipping, electronics, construction, electrical, etc. will find this book essential. The book will also serve the needs of engineers and specialists who have only a passing contact with polymers and additives in industrial setting need to know more.