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Example of Question

- Somerset Textile produces blue jeans and normally dyes them blue, but received an order for dark blue jeans. To meet this, black pigment was mixed into existing blue dye. - The process involves injecting black pigment into a blue dye storage tank. When the pigment injector plugged for 10 minutes, off-specification dark blue dye was produced. - It was calculated that 8 minutes worth of dye, or 160 liters, was produced outside the acceptable concentration range. At RM125 per liter, the total loss is RM20,000.

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Rama Krishna
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25 views

Example of Question

- Somerset Textile produces blue jeans and normally dyes them blue, but received an order for dark blue jeans. To meet this, black pigment was mixed into existing blue dye. - The process involves injecting black pigment into a blue dye storage tank. When the pigment injector plugged for 10 minutes, off-specification dark blue dye was produced. - It was calculated that 8 minutes worth of dye, or 160 liters, was produced outside the acceptable concentration range. At RM125 per liter, the total loss is RM20,000.

Uploaded by

Rama Krishna
Copyright
© © All Rights Reserved
Available Formats
Download as DOC, PDF, TXT or read online on Scribd
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UEMK3313 Step-by-Step Interactive

Blue jean is one of the popular fashions amongst the youngsters. Somerset Textile involves in
colouring the blue jean for 15 years. Normally, the production side prepares a batch of blue
colour dye last for three months consumption. This morning, the production department has
received an order to produce DARK BLUE colour jean (i.e. a new product series). Instead of
preparing new dye, the production side tried to mix black pigment in the early prepared batch
of blue colour dye to meet the desired dark blue colour. The supervisor was instructed to the
setup the blending system as shown in Figure below. The desired dark blue is produced using
black pigment at 800 ppm, with a minimum acceptable concentration of 700 ppm. Initially,
everything went smoothly with the desired dark blue dye has been produced for 2 hours. At
3.00 a.m. today, the black pigment injector plugged, and the pigment flow was interrupted for
10 minutes, until the supervisor realized the problem and unclogged the injector. What is the
loss if every liter of off-specification dark blue dye cost RM125.00 [Assumptions and Hints:
i) Negligible dynamics of the blue dye flow. ii) q1 q constant. iii) 1 ppm = 1 g / 1000 kg.
iv) Liquids density = 1010 kg/m3]
Step 1: Derive the process model and the transfer function
Step 2: Determine the duration of off-specification dark blue dye generated.
Step 3: Count the cost.
Blue dye
q1 = 20 liter/min

Injection of black
pigment, q2

V = 300 liters

20 liters/min Dark Blue Dye for jeans, q


(800 ppm black pigment in blue dye)

STEP 1
x = mass fraction of black pigment

dV
w1 w2 w
dt

d (Vx)
w1 x1 w2 x 2 wx
dt

d (Vx)
w1 x1 w2 x 2 wx
dt

d (Vx)
dx
dV
V
x
dt
dt
dt

dx
dV
x
w1 x1 w2 x 2 wx
dt
dt

dx
x ( w1 w2 w) w1 x1 w2 x 2 wx
dt

dV
1
w1 w2 w
dt

w
dx w1

( x1 x) 2 ( x 2 x)
dt V
V

Since negligible dynamics of blue dye flow and q1 q , thus no change of liquid volume,
dV
0
dt

Consider only
w
dx w1

( x1 x) 2 ( x 2 x)
dt V
V

Assume that
(i) x 2 1 for pure black pigment
(ii) x1 x 1
(iii) w1 w1
At initial steady state
0 w1 x1 w2 x 2 wx

d ( x 0)
w ( x1 x1 ) ( w2 w2 ) w ( x x )
dt

V dx
1
x1 w2 x
w dt
w
where

V
1
and K
w
w

dx
x1 Kw2 x
dt

Apply Laplace Transform

sX ( s ) X 1 ( s ) KW ( s ) 2 X ( s )
sX ( s ) X 1 ( s ) KW ( s ) 2 X ( s )
X ( s)

1
K
X 1 ( s )
W ( s ) 2
s 1
s 1

or

X ( s )

1
V
s 1
w

X 1 ( s )

w W (s)
2
V
s 1
w

STEP 2
From the derived transfer function in STEP 1, the blue dye stream q1 does not contain black
pigment and no change of its composition as well. Thus X 1 ( s ) 0 and

X ( s )

w W ( s)
2
V
s 1
w

Initially determine the amount of black pigment to achieve 800 ppm in the product
w1 q1

= 1010 kg/m3 0.020 m3/min


= 20.2 kg/min

w2
800 g
8 10 4 800 ppm or
1 10 6 g
w1 w2
w2 0.01617 kg/min

Since q1 q w1 w = constant
K

1
1

0.0495
w 20.2

V 0.3 1010

15 min
w
20.2
0.0495
W2 ( s )
15s 1

X ( s )

When pigment injection plugged


W2 ( s )

0.01617
s

8 10 4
0.0495 0.01617

s
s (15s 1)
15s 1

X ( s)

Since x (t ) x(t ) x

x (t ) 8 10 4 (1 e

15

x(t ) 8 10 4 8 10 4 (1 e

x(t ) 8 10 4 (e

15

15

To reach off-specification product < 700 ppm = 7 10-4

7 10 4 8 10 4 (e

15

15

t 2 min

Eventually, 10 2 = 8 min flow leaving at off specification

STEP 3

Since flow rate = 20 liter/min


8 min flow = 20 liter/min 8 min = 160 liter
Total loss = 160 liters x RM125/liter = RM 20,000 losses

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