Process Non-Uniformity Solution | Non-Uniform Process Solution

Overview

What is Process Non-Uniformity?

A non-uniform process is defined as a situation where production irregularities occur. For instance, a resin purging process may yield material that retains excessive hydrocarbons residuals, or, a drying process could consume excessive energy due to poor solids handling.

A non-uniform process results in inconsistent operation that can be difficult to control, generate waste, create safety hazards, and ultimately yield excessive operation and maintenance (O&M) costs.

Ratholing of material causing process issues.

Ratholing of material leads to using a hammer on the storage vessel

Flow problems from process non-uniformity are often resolved by hammering storage vessels, risking damage and downtime.

Process non-uniformity leading to dusting

Dangerous dusting as a result of issues with process non-uniformity.

Process tableting shows weight issues.

Challenge

Why is Process Non-Uniformity a Problem?

Process non-uniformities can place an enormous burden on the manufacturing operation and downstream supply chain. These burdens can include:

Product inconsistencies
Safety risks
Equipment failures
Poor process availability
Increased labor costs
Erratic product quality
Reduced production rate
Environmental hazards
Unscheduled maintenance
Customer complaints

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Factors

When & Where Can Process Non-Uniformity Occur?

Non-uniform processes can be the result of poorly operating equipment or system design. Unreliable flow through material handling equipment will negatively affect process uniformity. Common bulk material handling processes involve: