A few years ago,we increased the capacity of our batch reactor to 1,900 gal.from 1,200 gal.Our process produces about 364 BTU/lb of heat,so the cooling requirements went up about 1.5 MM BTU/hr.In addition,heating(with low-pressure steam/water)rose by 245,000 BTU/hr.Our quality engineer,in league with our control engineer,found that operators manually manipulate the steam and cooling water control valves to manage the temperatures.We've suffered 18% more temperature excursions where the operator lost control of the process for several minutes;off-product is up 2% but we're not having trouble blending out the reject.
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