Operational issues in solids processing plants: Systems view

A systematic approach to deal with the operational issues in solids process ing plants is presented. Potential problems in various equipment units are identified and classified according to continuum-scale phenomena: breakage, adhesion and cohesion, compaction, bulk solids flow problems, fluid-driven solids flow problems, and segregation. Analysis is performed in the contin uum and particle scales so as to identify the causal and opposing effects o f each problem. With appropriate mathematical models and empirical correlat ions, these effects can be related to equipment design, operating condition s, particle attributes, and material properties. The ratio of these competi ng effects shows whether a potential problem is a real concern and points t he direction for taking preventive measures. The action plan may include ch anging operating conditions or equipment design of a particular unit, or, m aking modifications to upstream equipment units. The method is illustrated with an industrial example: the production of potash.