QRR Chemical Engineering Optimization

Acetone/Water Distillation Column Case Study

Annual Cost Savings
$60K+
4.7% reduction per column
Energy Savings
400K+
kWh per year

Software-only solution

No hardware upgrades • Compatible with all DCS/PLC systems

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Process & Problem

System Specifications

  • Binary distillation: Acetone/Water separation
  • Feed rate: 100 kmol/hr
  • Column: 15 trays, atmospheric pressure
  • Target: >99.5% acetone purity

Critical Challenges

  • Fouling and energy losses - Progressive efficiency degradation
  • Off-spec production - Quality inconsistencies
  • Rising maintenance costs - Reactive approach
  • High operating costs - Baseline: ~$1.2M per year

Traditional fixed-parameter control cannot adapt to changing conditions

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QRR Modeling Approach

Comprehensive simulation tracking all critical parameters

Simulation Parameters

Tracks tray efficiency, flooding risk, energy use, fouling progression, and maintenance cycles in real-time

Conventional Control

  • Fixed energy input parameters
  • Reactive maintenance scheduling
  • No predictive management
  • Manual operator adjustments

QRR-Optimized

  • Adaptive control systems
  • Predictive fouling management
  • Real-time optimization
  • Automated performance tuning
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Validated Performance Results

Comprehensive analysis across all key performance indicators

Distillation Simulation Results

QRR optimization delivers measurable improvements across all metrics

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Business Impact

Energy Savings
400K+
kWh per year
Cost Reduction
$60K
Annual savings (4.7%)
Fouling Control
30%
Reduction in fouling rate
Hardware Upgrades
ZERO
Software-only solution

Zero-Risk Value Proposition:

  • No upfront investment - You don't pay until you see results
  • Compatible with existing systems - All DCS/PLC platforms
  • Rapid deployment - Weeks, not months
  • Scalable across facilities - Replicate success plant-wide
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Beyond Distillation

QRR optimization applies across your entire chemical engineering workflow

🔥 Reaction Vessels

  • Temperature optimization
  • Conversion efficiency improvement
  • Catalyst life extension
Typical: 3-8% cost reduction

♨️ Heat Exchangers

  • Fouling prediction & prevention
  • Energy efficiency gains
  • Predictive maintenance scheduling
Typical: 5-12% energy savings

🌀 Separators

  • Product purity control
  • Throughput optimization
  • Pressure management
Typical: 4-10% yield improvement

⚗️ Crystallizers

  • Crystal size distribution control
  • Yield maximization
  • Quality consistency
Typical: 5-15% yield increase
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Transform Your Process Efficiency

Ready to optimize your chemical processes?

Potential Plant-Wide Impact

Typical Chemical Plant: 10-20 major process units

Average Savings per Unit: $50-200K annually

Plant-Wide Potential: $500K - $4M Annual Savings

Schedule a Process Assessment

Robin Macomber

relationalrelativity@gmail.com

805-621-0987

Relational Relativity LLC — Optimizing Chemical Processes Through Mathematics

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